®

HIGH TENSION XLPE CABLES (UP TO 45 kV)

P R O D U C T R A N G E

■
L.T. PVC & XLPE POWER CABLES WITH
COPPER / ALUMINIUM CONDUCTOR (1100 V.
UPTO 4 CORE X 630 SQ. MM., 1 CORE X
1000 SQ. MM.)
■
L.T PVC & XLPE CONTROL CABLES
(1100 V. UPTO 61 CORE X 1.5 & 2.5 SQ.MM.)
■
H.T. XLPE CABLES UPTO 132 kV
■
FIRE SURVIVAL, ZERO HALOGEN CABLES
■
THERMO COUPLE COMPENSATING & EXTENSION
CABLES
■
INSTRUMENTATION CABLES SCREENED /
UNSCREENED
■
FRLS / FR / HR / HFFR / HOFR / RUBBER –
POWER, CONTROL & INSTRUMENTATION
CABLES
■
HT / LT AERIAL BUNCHED CABLES
■
RAILWAY SIGNALLING CABLES
■
TELEPHONE CABLES – DRY & JELLY FILLED
■
ACSR & AAAC CONDUCTORS
■
MINING / WELDING – RUBBER CABLES
■
EPR / SILICONE / HIGH TEMP. CABLES
■
SUBMERSIBLE CABLES
■
COAXIAL CABLES
■
BUILDING WIRES & FLEXIBLES (SINGLE & MULTICORE)
■
LAN CAT-5 / 5E, 6 CABLES
■
PVC PIPES & ACCESSORIES
■
INDUSTRIAL PLUGS & SOCKETS
CONTENTS AN ISO 9001:2000
COMPANY

Page No.

● COMPANY PROFILE 2
● MANUFACTURING PROCESS-AT POLYCAB 3
● FLOW CHART 4
● CONSTRUCTION OF HT CABLES 5
● QUALITY ASSURANCE 6
● FLAME RETARDANT LOW SMOKE CABLES 7
● ADVANTAGES OF POLYCAB CABLES & SELECTION OF CABLES 8
● POLYCAB GUIDLINES FOR SELECTION OF CABLES 9
● TECHNICAL DATA
■ Conductor Resistance 10
■ Cable Short Circuit Rating
■ Capacitance & Reactance 11
■ Current Rating 13
■ Rating Factors 14
● WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF CABLES
■ 3.8 / 6.6 KV (E) HT XLPE SINGLE CORE 16
■ 6.35/11 KV (E) 6.6/6.6KV (UE) HT XLPE SINGLE CORE 17
■ 11/11 KV (UE) HT XLPE SINGLE CORE 18
■ 12.7/22 KV (E) HT XLPE SINGLE CORE 19
■ 19/33 KV (E) HT XLPE SINGLE CORE 20
■ 33/33 KV (UE) HT XLPE SINGLE CORE 21
■ 1.9/3.3 KV (E)&3.3/3.3 KV (UE) HT XLPE THREE CORE 22
■ 3.8/6.6 KV (E) HT XLPE THREE CORE 23
■ 6.35/11 KV (E) HT XLPE THREE CORE 24
■ 11/11 KV (UE) HT XLPE THREE CORE 25
■ 12.7/ 22 KV (E) HT XLPE THREE CORE 26
■ 19/33 KV (E) HT XLPE THREE CORE 27
■ 33/33 KV (UE) HT XLPE THREE CORE 28
● HANDLING STORAGE & LAYING OF CABLES 29
● IMPORTANT FORMULA 31
● DIFFERENCE BETWEEN EARTHEDIUNEARTHED SYSTEM 32

1
 COMPANY PROFILE AN ISO 9001:2000
COMPANY
• Technical Support for Applications/
POLYCAB, an ISO 9001: 2000 company Projects
is the largest Wire & Cable
manufacturer in India with a proven
track record of over three decades. The
fastest growing company in the Indian
Cable Industry with consistent growth of
more then 40% per annum for the last 3
years. Polycab group has crossed Rs. 1500
crore turnover and is set to achieve Rs.
2000 crore turnover in the year 2006 –
07.

From a modest beginning with Wires and

Cables, over three decades ago Polycab
set up State of Art manufacturing
facilities at Daman in 1996. In the
manufacture of cables, a competitive
edge lies not so much in product
innovation as in consistent quality and
ready availability. Polycab’s Daman factory
was created to address these key
market determinants. The
manufacturing set up is sourced out
from the world renowned Machinery and
Technology suppliers with constant
upgradation and expansions.

In an on going process to improve

Customer Satisfaction Polycab offers a
variety of services:
• Commercially competitive prices.
• Reliable & consistent quality.
• Reliable & just in time delivery.
• Product development for a changing
market.
• A targeted stocking policy.

2
 CONTENTS AN ISO 9001:2000
COMPANY
Several thousands kilometers of HV XLPE
Cables in the voltage range of 6.6KV,
11KV, 22KV & 33KV have been
manufactured and are in operation in
India and abroad.

Polycab HV XLPE Cables are preferred

choice in Power
Plants,DistributionSystems,Heavy Industries,
POLYCAB derives its strength from its
Various Utilities, The Titans of Indian
customers. The growth of the latter is a
Industry & Consultants / Specifiers.
prerequisite to the growth of the
company and hence customers’
satisfaction is its prime objective. Over
the years sincere service and
dedication to its Customers has earned
the Company distinguished Customers
which includes leaders in Sectors like
Utilities, Power Generation,
Transmission & Distribution, Petroleum
& Oil Refineries, Oem’s, EPC contractors,
Steel & Metal, Cement, Chemical,
Atomic Energy, Nuclear Power,
Consultants & Specifiers etc.

POLYCAB has highly experienced

qualified and dedicated professionals
with strong adherence to the
qualitymanagementsystem.Polycab has
offices all over the country and also has a
wide network of authorized distributors
and dealers to cater to all the
customer segments in India and
abroad.

POLYCAB has earned the trust and

reputation in India and abroad by
winning the customers’ confidence.

3
MANUFACTURING PROCESS – AT POLYCAB AN ISO 9001:2000
COMPANY

POLYCAB HV XLPE cables are manufactured discharges, as small as one pico-coulomb.

at its most modern manufacturing setup Such defects lead to gradual deterioration
in DAMAN. Manufacture of HV XLPE of the XLPE and eventually breakdown may
CABLES requires great care and skill at all occur.
stages of processing.Work on HV cables has
showntoraise the electric stress of XLPE cables
it is essential that the extruded
insulation is of high cleanliness without
any imperfection, free of contamination,
voids and manufacturing defects, and
that the screen interface is smooth. In
addition an integrated extrusion plant
employing a Continuous
CentenaryVulcanizing(CCV) process line(Dry
Curing Line) is required.Polycabeasilymet
these two criteria by carefully selecting
imported insulating materials and by
installing 2 CCV lines sourced from world
renowned manufacturers. (Fig 1)

The cable core is triple extruded and

crosslinked in the fully enclosed process
in which the inner semi-conducting
screen, the XLPE insulation and the
outer semi conducting screen are
applied simultaneously (Fig 2) to the pre-
heated cable conductor. Specialized in-
line inspection techniques using X-rays
are employed to monitor the dimensional
accuracy of the extruded core. These
examinations confirm the correct levels
of dimensional accuracy.

The final stage of HV cable manufacture

is the high voltage test, which
comprises an HV withstand, and a partial
discharge detection test. These tests take
place in Polycab’s sophisticated HV Test
Lab (Fig 3). The tests are of short duration,
typically 30 minutes, and are capable of
detecting the defects that initiate partial

3
 FLOW CHART AN ISO 9001:2000
COMPANY

Figure1 : 2 CCV (DRY CURE) LINES

Figure 2 : THREE LAYER COMON TRIPLE EXTRUSION METHOD

Figure3 : ULTRA MODERN HV TESTING LAB

4
MANUFACTURING PROCESS – AT POLYCAB AN ISO 9001:2000
COMPANY

Conductor
Quality Checks
No. of Wires, Size, Conductor Resistance, Surface Finish, Diameter of Conductor

Continuous Triple Extrusion

Inner Semicon, XLPE Insulation Outer Semicon
Quality Checks
Type of Compounds, B atch No. details, Thickness, Core D ia, Eccentricit y, S ur face Finish, Hot Set
Test
Copper Taping
Quality Checks
Size & Type of Tape, Market /Lot No., Overlap, Dia over tape, Continuity, Tape Jointing, Core Identification

Laying –Up / Twisting

Quality Checks
Core Sequence, No of Cores, Laylength., Binder /Roundness

Inner Sheathing (Extrusion*)

Quality Checks
Type of PVC, Batch/Lot No., Thickness of Sheath, Dia over Sheath

Armouring
Quality Checks
Armour Dimensions, No. of Armour, Coverage, Armour Joint

Outer Sheathing
Quality Checks
Type of PVC, Batch/Lot No., Thickness of Sheath, Dia over Sheath, Color, Surface Finish

Final Testing
Quality Checks
Conductor Resistance, High Voltage Test, Partial Discharge Test

Packing / Marking
Quality Checks
Marking Details, Lagging Coverage
* Lead Sheath (optional)

Storage / Dispatch
Cables with FRLS / Zero Halogen Outer Sheath can be supplied against specific requirement.

5
CONSTRUCTION OF HT CABLES AN ISO 9001:2000
COMPANY

1. Conductor : Stranded Class 2 - Annealed Plain / Tinned

Copper / Aluminium - IS:8130 / IEC 60228/
BS 6360.
2. Conductor Screen : Extruded semi-conducting compound – IS:7098 Part 2,
IEC:60502 Part – 2, BS:6622, BS:7835.
3. Insulation : XLPE – IS : 7098 Part 2, IEC:60502 Part – 2, BS:6622, BS:7835.
4. Insulation Non-metallic Screen : Extruded semi-conducting compound – IS:7098 Part 2,
IEC:60502 Part – 2, BS:6622, BS:7835.
5. Insulation Metallic Screen : Copper Wire / Tape or Aluminium Wire / Strip – IS:7098 Part 2,
IEC:60502 Part – 2, BS:6622, BS:7835.
6. Fillers : Non Hygroscopic PVC * / Polypropelene
Fiber to maintain roundness of cable.
7. Inner sheath/Bedding : PVC ST 2 as per IS:7098 Part 2, IEC:60502 Part – 2,
BS:6622, LSOH to BS:7835.
8. Armour : IS:7098 Part 2, IS: 3975, IEC:60502 Part – 2, BS:6622, BS:7835.
9. Outer Sheath : PVC ST 2, FR, FRLS as per IS:7098 Part 2, IEC:60502
Part – 2, BS:6622, LSOH to BS:7835.
Flame Retardant (FR), Flame Retardant Low Smoke (FRLS) and Low Smoke Zero Halogen &
Flame Retardant (LSOH) Sheathed HT XLPE cables are also manufactured.

* Weights given in the Tables are with PVC Fillers.

Polycab manufactures following voltage grade cables as per IS-7098[Part-2],

IEC-60502 Part-2 and BS-6622 & BS:7835

ALUMINIUM WIRE
XLPE
/ STRIP • 45 kV or 33 kV (UE) Screened XLPE Cables
ARMOUR
INSULATION INNER SEMICON as per customer requirement.
• 19/33 kV Screened Cable i.e. 33 kV (E)
TAPE
COPPER 12.7/22 kV Screened Cables i.e. 22 kV
• (E) 11/11 kV Screened Cables. i.e. 11 kV (
• UE)
• 6.35/11 kV, Screened Cables i.e. 6.6 kV (UE)
• 3.8/6.6 kV Screened Cables.

SIZES:
PVC
FILLERS • 50 Sq.mm up to 1000 Sq.mm in Single Core
OUTER SEMICON
Cables.
ST2 PVC INNER SHEATH • 35 Sq.mm to 400 Sq.mm in Multi Cores
STRANDED COMPACTED
ST2 PVC OUTER COPPER / ALUMINIUM
SHEATH CONDUCTOR
5
 QUALITY ASSURANCE AN ISO 9001:2000
COMPANY

Polycabs goal is to have satisfied ERDA Vadodara. Short circuit tests on cable
customers. Quality assurance consisting conductor and armour are successfully
of rigorous inspection followed by
carried at CPRI Bhopal & ERDA Vadodara.
meticulous process and quality control
in all phases, guarantees the superior
quality of POLYCABS products. Up-to-
Date laboratory facilities ensure that
quality control requirements are met in
full. Polycab XLPE Cables are tested to
ensure high reliability in performance.
Continuous process monitoring and post
manufacturing tests ensure the
compliance to Indian and International
Standards. The assurance of quality is
further ensured by ISI certification No.
CM/L-7180366 on cables and ISO 9001
certification by UL, USA, A-7913.

QUALITY ASSURANCE TESTING :

Polycab is self sufficient to carry out all
Routine & Type Tests in its own laboratory.
It has world class Testing facilities for
Routine & Type Tests. Routine Tests :
IS:7098 Part 2, IEC:60502, BS:6622,
BS:7835
• Partial Discharge Test
• High Voltage Test
• Conductor Resistance Test. Routine Tests
are performed on each manufactured
length of cable in Routine Test
Laboratory.

TYPE TESTS:
IS:7098 Part 2, IEC:60502, BS:6622, BS:7835
a) Electrical Type Tests
b) Non-Electrical Type Tests
c) Special Tests.
The cable samples are type tested in-
house to ensure conformance as to
various standards.

Polycab cables of various voltage

grades are type tested at CPRI Bangalore &
6
 CONSTRUCTION OF HT CABLES AN ISO 9001:2000
COMPANY

IMPULSE TEST SET UP

NON ELECTRICAL TYPE TEST LABORATORY

7
FLAME RETARDANT LOW SMOKE CABLES AN ISO 9001:2000
COMPANY

The behaviour of Electric Cables in FRLS PVC compound should ensure the
presence of fire has been a matter of following :
great concern to all Electrical Engineers
1) Minimum smoke emission.
involved in Generation, Transmission
and Utilisation of electric power. 2) Very low toxic and corrosive fumes emission.
Normally all XLPE Cables have an outer
3) Fire Retardant characteristics.
sheath of PVC. Although PVC by itself is
flame retarding, it does produce highly Our laboratory is well equipped with latest
toxic and corrosive fumes in the event of test equipments to carry out following test
fire. requirements.
As a matter of fact, in closed and crowded a) The oxygen index and temperature
places such as power stations, subways, index of sheath as per ASTM-D 2863.
railways with long sections in tunnels, b) Flammability characteristics of cable
road tunnels, ships, hospitals, schools, as per IEC-332 ( Pt. I ) & IEC-332 ( Pt. III )
hotels, cinema theatres, museums and
c) Flammability characteristics of cables
public premises in general, besides the
as per Swedish Standard SS 424 14 75,
obvious danger represented by fire
Class F3.
propagation, also fume toxicity and
opacity are particularly important as d) Determination of the amount of

they may cause, with equally serious halogen acid gas

consequences for human safety, evolvedduringcombustion of

suffocation intoxication and panic due to outersheath materials as per per IEC

reduced visibility. 754 ( Pt. I ).

e) Determination of smoke generation
of outersheath material under fire as
per ASTM-
D 2843
f) The measurement of smoke density as
per IEC 61034.

7
 ADVANTAGES OF POLYCAB XLPE CABLES AN ISO 9001:2000 COMPANY

● Higher Electrical Strength Retention

● Higher Short Circuit Rating
● Better Electrical , Mechanical & Thermal Properties
● Easy Jointing & Termination

SELECTION OF CABLES
Power Cables are generally selected All sizes of POLYCAB XLPE cables are
considering the application. However, designed to standard operating
following factors are important for conditions in India and abroad. The
selection of suitable cable construction standards adopted are considering the
required to transport electrical energy geographical/climatical conditions and
from one end to the other. general applications of power for
1) Maximum operating voltage, utilities, distribution and generation
2) Fault Level, purposes.

3) Load to be carried, The cables are manufactured

4) Possible overloading duration & conforming to Indian & International
magnitude, cables specifications for XLPE Insulated
5) Route length and voltage drop. cables. Customer specific requirements
can also be met.
6) Mode of installation considering
installation environment such as
ambient & ground temperature
chemical & physical properties of soil.
7) Flame retardant properties.

8
POLYCAB GUIDELINES FOR SELECTION OF AN ISO 9001:2000
COMPANY

CABLES
Polycab is manufacturing wide range of cables, so it is important that while placing
enquiries or orders, as much information as possible shall be given to Polycab, so that
the enquiries and orders are dealt quickly and efficiently.

1) Voltage Grade : 1.9/3.3kV(E),3.3/3.3kV(UE),3.8/6.6kV(E),6.6/6.6kV(UE),6.35/11kV(E),

11 / 11 kV (UE), 12.7 / 22 kV (E) & 33 kV (E), 33 kV (UE) & 45 kV
2) Relevant Indian Standard : IS 7098 (Part-2) – 1985 or International standard – IEC-60502 (Part-
2),
BS-6622 & BS:7835.
3) Number of cores. : Single & Three.
4) Conductor : Size - 35 Sq.mm to 1000 Sq.mm in Single Core Cables & 35
Sq.mm to 400 Sq.mm in 3Core cables.
5) Conductor Material : Copper / Aluminium
6) Type of Insulation : XLPE
7) Type of Inner Sheathing : PVC Wrapped / PVC Extruded.
8) Type of Armour : Unarmoured / Strip Armoured / Round Wire Armoured.
9) Type of Outer Sheath : PVC / Flame Retardant / Flame Retardant Low Smoke /
Zero Halogen (LSOH).
10) Length of cable required and drum length.

9
 CONDUCTOR RESISTANCE AN ISO 9001:2000 COMPANY

The details to the above Guidelines are given in tables.

Table - 1 *Conductor Technical Information for Single Core and Multicore cables
conforming to IS-8130 /1984 (Stranded –Class-2) Copper & Aluminium
Conductors.

Nomina Minimum no. of wires Max. D.C. Resistance at 20oC A.C. Resistance at 90oC
l Size of
Conduct Compacted Round Plain Copper Aluminium Plain Copper Aluminium
or
Sq.mm CU. ALU. Ohm/Km Ohm/Km Ohm/Km Ohm/Km
25 6 6 0.727 1.20 0.930 1.54
35 6 6 0.524 0.868 0.671 1.11
50 6 6 0.387 0.641 0.495 0.82
70 12 12 0.268 0.443 0.343 0.567
95 15 15 0.193 0.320 0.247 0.410
120 18 15 0.153 0.253 0.196 0.324
150 18 15 0.124 0.206 0.159 0.264
185 30 30 0.0991 0.164 0.127 0.210
240 34 30 0.0754 0.125 0.0965 0.160
300 34 30 0.0601 0.100 0.0769 0.130
400 53 53 0.0470 0.0778 0.0602 0.10
500 53 53 0.0366 0.0605 0.0468 0.0774
630 53 53 0.0283 0.0469 0.0362 0.060
800 53 53 0.0221 0.0367 0.0283 0.0470
1000 53 53 0.0176 0.0291 0.0225 0.0372

* Conductor meeting requirements of IEC-60228 and BS 6360 can also be manufactured.

Table - 2 SHORT CIRCUIT RATING FOR 1 SECOND DURATION FOR COPPER AND
ALUMINIUM XLPE CABLES (CURRENT IN K. AMPS)
XLPE Cables as per
Nominal IS-7098 (Part-2)-1985
Size XLPE Insulated
Sq.mm Copper Aluminium
1) Max. Conductor Temperature during operation: 90oC
25 3.6 2.4
35 5.0 3.3 2) Max. Conductor Temperature during short
50 7.1 4.7
Circuit: 250o C Formula relating Short Circuit
70 10.0 6.6
95 13.6 9.0 Rating with duration
120 17.1 11.3
It = I sh Where
150 21.4 14.2
 t It = Short Circuit Rating for t
185 26.4 17.5
240 34.3 22.6 Seconds. t = duration in
300 42.9 28.3
seconds
400 57.1 37.7
500 71.4 47.2
I sh = Short Circuit rating for 1 second.
630 90.0 59.4
800 114.3 75.5
1000 142.9 94.3

10
CAPACITANCE AN ISO 9001:2000
COMPANY

Table - 3 CAPACITANCE
Approximate Capacitance (Microfarads/km) for Single Core Cables
Size Voltage Grade(kV)

1.9/3.3 & 3.3/3.3 3.8/6.6 6.6/6.6 & 11/11 12.7/22 19/33 33/33
6.35/11
35
50 0.30 0.27 0.23

70 0.34 0.31 0.27 0.18

95 0.39 0.34 0.31 0.20 0.19 0.15 0.14

120 0.43 0.37 0.33 0.22 0.20 0.16 0.15

150 0.49 0.42 0.36 0.24 0.22 0.17 0.16

185 0.52 0.44 0.39 0.25 0.24 0.18 0.17

240 0.59 0.50 0.43 0.28 0.26 0.20 0.19

300 0.67 0.53 0.48 0.32 0.30 0.23 0.20

400 0.76 0.55 0.53 0.36 0.33 0.25 0.23

500 0.77 0.57 0.50 0.39 0.36 0.27 0.25

630 0.81 0.64 0.69 0.43 0.40 0.29 0.28

800 0.86 0.73 0.79 0.49 0.45 0.33 0.30

1000 0.88 0.80 0.88 0.53 0.49 0.35 0.33

Table - 4 CAPACITANCE
Approximate Capacitance ( Microfarads/km) For Three Core Cables

Size Voltage Grade(kV)

1.9/3.3& 3.8/6.6 6.6/6.6 & 11/11 12.7/22 19/33 33/33

3.3/3.3 6.35/11
35 0.24 0.25 0.21
50 0.27 0.27 0.22

70 0.31 0.31 0.25 0.19

95 0.35 0.35 0.29 0.21 0.20 0.15 0.14

120 0.39 0.38 0.31 0.23 0.22 0.16 0.15

150 0.42 0.43 0.34 0.25 0.23 0.18 0.16

185 0.46 0.45 0.36 0.27 0.25 0.18 0.17

240 0.51 0.51 0.41 0.30 0.28 0.20 0.19

300 0.57 0.54 0.46 0.33 0.31 0.23 0.20

400 0.63 0.57 0.52 0.37 0.34 0.25 0.23

11
 REACTANCE AN ISO 9001:2000
COMPANY

Table - 5 REACTANCE
Approximate Reactance At 50 Hz( Ohms/km) For Single Core Cables
Size Voltage Grade(kV)
1.9/3.3& 3.8/6.6 6.6/6.6 & 11/11 12.7/22 19/33 33/33
3.3/3.3 6.35/11
Arm Un-Arm Arm Un-Arm Arm Un-Arm Arm Un-Arm Arm Un-Arm Arm Un-Arm Arm Un-Arm
35
50 0.115 0.104 0.119 0.110 0.133 0.127 0.133 0.125 0.137 0.130 0.147 0.140

70 0.109 0.098 0.113 0.105 0.123 0.118 0.126 0.119 0.130 0.123 0.141 0.133

95 0.104 0.095 0.108 0.100 0.116 0.111 0.120 0.114 0.124 0.116 0.135 0.127 0.143 0.137
120 0.100 0.092 0.104 0.101 0.112 0.107 0.117 0.110 0.119 0.112 0.130 0.122 0.137 0.131

150 0.096 0.088 0.101 0.093 0.109 0.104 0.112 0.106 0.115 0.107 0.126 0.118 0.134 0.129
185 0.094 0.087 0.099 0.091 0.107 0.101 0.110 0.103 0.114 0.105 0.124 0.115 0.128 0.122

240 0.091 0.084 0.096 0.089 0.104 0.097 0.106 0.100 0.110 0.101 0.118 0.110 0.124 0.118
300 0.088 0.081 0.093 0.086 0.100 0.094 0.102 0.096 0.105 0.097 0.112 0.105 0.120 0.114

400 0.086 0.079 0.091 0.085 0.096 0.091 0.098 0.092 0.101 0.093 0.119 0.102 0.115 0.109
500 0.085 0.078 0.088 0.083 0.093 0.089 0.095 0.090 8.099 0.091 0.105 0.099 0.111 0.106

630 0.083 0.077 0.087 0.081 0.092 0.086 0.094 0.087 0.095 0.089 0.101 0.096 0.108 0.103
800 0.082 0.076 0.085 0.077 0.089 0.084 0.091 0.085 0.092 0.086 0.097 0.092 0.106 0.099

1000 0.081 0.075 0.084 0.076 0.087 0.082 0.088 0.083 0.090 0.085 0.096 0.090 0.102 0.096

Table - 6 REACTANCE
Approximate Reactance At 50 Hz ( Ohms/km) For Three Core Cables
Size Voltage Grade(kV)

1.9/3.3& 3.8/6.6 6.6/6.6 & 11/11 12.7/22 19/33 33/33

3.3/3.3 6.35/11
35 0.094 0.104 0.111
50 0.087 0.098 0.104

70 0.084 0.094 0.100 0.129

95 0.081 0.090 0.095 0.123 0.125 0.121 0.131

120 0.078 0.087 0.092 0.117 0.120 0.116 0.125

150 0.076 0.085 0.089 0.114 0.116 0.112 0.122

185 0.075 0.083 0.087 0.110 0.113 0.110 0.116

240 0.073 0.081 0.085 0.106 0.108 0.105 0.112

300 0.072 0.079 0.082 0.103 0.105 0.100 0.108

400 0.071 0.078 0.079 0.099 0.101 0.097 0.103

Note: All figures given in various tables are indicative only.

12
CURRENTS RATINGS AN ISO 9001:2000
COMPANY

POLYCAB RECOMMENDATIONS FOR Depth of laying (to the highest point of

CURRENT RATINGS: the cables laid direct in the ground )
The current rating of power cable is 1) 3.3, 6.6 & 11kV Cables : 90 cm
defined by the maximum intensity of
2) 22 and 33kV Cables : 105 cm
current (amperes) which can flow
continuously through the cable, under *Max. Conductor temperature
permanent loading conditions, without at the end of a short circuit : 250° C
any risk of damaging the cable or
deterioration of its electrical properties. To obtain the maximum current carrying
capacity of a cable operating at different
The value given in the tables are valid conditions from the standard, various
for one circuit in a three phase system rating factors are to be multiplied, as
under conditions specified. For grouping follows :
cables rating factors must be used.

The current carrying capacities I a = K X Is in amperes Where ;

mentioned in POLYCAB technical data are
intended as a guide, to assist operating I a : Current rating at actual operating
conditions (amperes)
engineers in selecting cables for safety
Is : Current rating at standard
and reliability. operating conditions
(amperes)
Basic assumptions and conditions of installation :
K : Rating factor as, applicable.
1) Maximum Conductor Temperature :
90° C
2) Ambient Ground Temperature : 30° C
3) Ambient Air Temperature : 40° C
4) Thermal resistivity of soil : 150°
C.
Cm/
W

13
 RATING FACTORS AN ISO 9001:2000
COMPANY

A). FOR AIR AND GROUND TEMPERATURE.

A. Rating factors for variation in ambient air temperature.
Ambient Temp (oC) 25 30 35 40 45 50
Rating Factors 1.14 1.10 1.04 1.00 0.95 0.90
B. Rating factors for variation in ground temperature.
Ground Temp (oC) 15 20 25 30 35 40 45
Rating Factors 1.12 1.08 1.03 1.00 0.96 0.91 0.87

B). FOR DEPTH OF LAYING (CABLES LAID DIRECT IN THE GROUND)

Depth of laying (cm) 3.3kV, 6.6kV & 11kV all sizes 22kV & 33 kV all Size
90 1
105 0.99 1
120 0.98 0.99
150 0.96 0.97
180 or more 0.95 0.96

C). FOR VARIATION IN THERMAL RESISTIVITY OF SOIL

Thermal
100 120 150 200 250 300
Resistivity of
Soil (oCcm/w)
Factor 1.20 1.11 1.0 0.89 0.80 0.73

GROUP RATING FACTORS FOR SINGLE-CORE CABLES

A).Cables laid direct in the ground in horizontal formation.
Number of
trefoils in Spacing between trefoils 3.3 to 22kV cables 33 kV Cables.
group
Touching 15 cm 30 cm 45 cm Touching 15 cm 30 cm 45 cm
2 0.78 0.81 0.85 0.88 0.80 0.82 0.85 0.88
3 0.68 0.71 0.77 0.81 0.68 0.71 0.76 0.79
4 0.61 0.65 0.72 0.76 0.62 0.65 0.71 0.75
5 0.56 0.61 0.68 0.73 0.57 0.60 0.67 0.72

B). Cables laid on Racks / Trays in covered trench with removable covers where air
circulation is restricted, Trefoils are separated by two cable diameter horizontally and the
trays are in tiers having 300 mm distance.
No. of Trefoils in Horizontal formation
No. racks/trays in tiers
1 2 3
1 0.95 0.90 0.88
2 0.90 0.85 0.83
3 0.88 0.83 0.81
6 0.86 0.81 0.79

14
RATING FACTORS AN ISO 9001:2000
COMPANY

C). As above B. but c ables laid in open air.

No. of Trefoils in Horizontal formation
No. racks/trays in tiers
1 2 3
1 1 0.98 0.96
2 1 0.95 0.93
3 1 0.94 0.92
6 1 0.93 0.90

FOR MULTI-CORE CABLES:

A) Cables laid inside concrete trench with removable covers, on cable trays where air
circulation is restricted.The cables spaced by one cable diameter and trays are in tiers
spaced by 300 mm.The clearance between the wall and the cable is 25 mm.
No. of cables No. of cables
trays in 1 2 3 6 9
tier
1 0.95 0.90 0.88 0.85 0.84
2 0.90 0.85 0.83 0.81 0.80
3 0.88 0.83 0.81 0.79 0.78
6 0.86 0.81 0.79 0.77 0.76

B) Cable laid on cable trays exposed to air , the cables spaced by one cable
diameter and trays are in tiers spaced by 300 mm. The clearance of the cable from
the wall is 25 mm.
No. of cables No. of cables
trays in 1 2 3 6 9
tier
1 1 0.98 0.96 0.93 0.92
2 1 0.95 0.93 0.90 0.89
3 1 0.94 0.92 0.89 0.88
6 1 0.93 0.90 0.87 0.86

C) Cables laid on cable trays exposed to air, the cables touching and trays are in tiers
spaced by 300 mm. The clearance between the wall and the cable is 25 mm.
No. of cables per tray
No. of cables
trays. 1 2 3 6 9
1 1 0.84 0.80 0.75 0.73
2 1 0.80 0.76 0.71 0.69
3 1 0.78 0.74 0.70 0.68
6 1 0.76 0.72 0.68 0.66

D) Cables laid direct in ground in horizontal formation

Distance of cables
No. of cables in group
Touching 15 mm 30 mm 45 mm
2 0.79 0.82 0.87 0.90
3 0.69 0.75 0.79 0.83
4 0.62 0.69 0.74 0.79
5 0.58 0.65 0.72 0.76

15
 WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF AN ISO 9001:2000
COMPANY

CABLES
6 0.54 0.61 0.69 0.75

The above data is approximate and subject to manufacturing tolerance.

* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.
16
RATING FACTORS AN ISO 9001:2000
COMPANY

TABLE 7-3.8 / 6.6 KV (E) HT XLPE SINGLE CORE ALUMINIUM CONDUCTOR CABLES
“POLYCAB” SINGLE CORE ALUMINIUM CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES
CONFORMING TO IS: 7098 PART-2/1985:
UNARMOURED CABLE ALUMINIUM STRIP ARMOURED ALUMINIUM ROUND WIRE ARMOURED CURRENT CARRYING
Nomina
Nomina Minimu CABLE CABLE CAPACITY
l *Norm
l Nomin Approx. Approx m Nomin Minimu Approx Approx Nomin Minimu Approx Approx In In Duct In Air
Thicknes al
Size al Overall . Weight Thicknes al m . . Weight al m . . Weight Ground at at
s of Thicknes Diaete of Deliver
of s of Dimesio Thicknes Overall of Dimesio Thicknes Overall of at 30° 40°
XLPE y
Conducto s of r of Cable. Inner n of s of Diamete Cable. n of s of Diamete Cable. 30° C. C. C.
Insulatio PVC Cable. Length
r Sheath Strip PVC r of Roun PVC r of
n .
Outer Outer Cable. d Outer Cable.
Sheath Sheath Wire Sheath
Sq.mm mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
.
35 2.8 2.0 20.0 450 0.30 0.8 1.4 21.0 550 1.6 1.40 22.5 620 120 105 145 500
50 2.8 2.0 21.0 500 0.30 0.8 1.4 22.0 600 1.6 1.40 23.5 700 140 125 170 500
70 2.8 2.0 23.0 600 0.30 0.8 1.4 24.0 750 1.6 1.40 25.5 800 175 155 215 500
95 2.8 2.0 24.5 750 0.30 0.8 1.4 25.5 850 1.6 1.40 27.0 950 205 180 260 500
120 2.8 2.0 26.0 850 0.30 0.8 1.4 27.0 950 1.6 1.40 29.0 1050 235 205 305 500
150 2.8 2.0 27.0 950 0.30 0.8 1.4 28.5 1100 1.6 1.56 30.5 1200 260 230 345 500
185 2.8 2.0 29.0 1100 0.30 0.8 1.56 31.0 1250 1.6 1.56 32.5 1400 295 260 395 500
240 2.8 2.2 32.0 1350 0.40 0.8 1.56 33.0 1500 2.0 1.56 35.5 1700 340 300 470 500
300 3.0 2.2 34.5 1550 0.40 0.8 1.56 36.0 1750 2.0 1.56 38.0 2000 385 335 540 500
400 3.3 2.2 38.5 1950 0.40 0.8 1.56 40.0 2200 2.0 1.72 42.5 2450 440 380 630 500
500 3.5 2.4 42.0 2400 0.50 0.8 1.72 43.5 2650 2.0 1.88 46.5 2950 495 430 730 500
630 3.5 2.4 45.5 2850 0.50 0.8 1.88 47.5 3200 2.0 1.88 50.0 3450 560 480 840 500
800 3.5 2.6 50.0 3450 0.50 0.8 1.88 51.0 3750 2.5 2.04 55.0 4300 620 530 960 500
1000 3.6 2.8 55.0 4250 0.60 0.8 2.04 56.5 4600 2.5 2.20 60.5 5150 680 580 1070 500

TABLE 8 - 3.8 / 6.6 KV (E) HT XLPE SINGLE CORE COPPER CONDUCTOR CABLES
“POLYCAB” SINGLE CORE COPPER CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES CONFORMING TO IS:
7098 PART-2/1985:
UNARMOURED CABLE ALUMINIUM STRIP ARMOURED ALUMINIUM ROUND WIRE ARMOURED CURRENT CARRYING
Nomina
Nomina Minimu CABLE CABLE CAPACITY
l *Norm
l Nomin Approx. Approx m Nomin Minimu Approx Approx Nomin Minimu Approx Approx In In Duct In Air
Thicknes al
Size al Overall . Weight Thicknes al m . . Weight al m . . Weight Ground at at
s of Thicknes Diaete of Deliver
of s of Dimesio Thicknes Overall of Dimesio Thicknes Overall of at 30° 40°
XLPE y
Conducto s of r of Cable. Inner n of s of Diamete Cable. n of s of Diamete Cable. 30° C. C. C.
Insulatio PVC Cable. Length
r Sheath Strip PVC r of Roun PVC r of
n .
Outer Outer Cable. d Outer Cable.
Sheath Sheath Wire Sheath
Sq.mm. mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
35 2.8 2.0 20.0 670 0.30 0.8 1.4 21.0 750 1.6 1.40 22.5 850 155 140 185 500
50 2.8 2.0 21.0 850 0.30 0.8 1.4 22.0 900 1.6 1.40 23.5 1000 185 160 220 500
70 2.8 2.0 23.0 1050 0.30 0.8 1.4 24.0 1150 1.6 1.40 25.5 1250 225 195 275 500
95 2.8 2.0 24.5 1300 0.30 0.8 1.4 25.5 1450 1.6 1.40 27.0 1550 265 235 340 500
120 2.8 2.0 26.0 1600 0.30 0.8 1.4 27.0 1700 1.6 1.40 29.0 1800 300 265 390 500
150 2.8 2.0 27.0 1900 0.30 0.8 1.4 28.5 2050 1.6 1.56 30.5 2150 335 295 440 500
185 2.8 2.0 29.0 2250 0.30 0.8 1.56 31.0 2400 1.6 1.56 32.5 2550 380 330 510 500
240 2.8 2.2 32.0 2850 0.40 0.8 1.56 33.0 3000 2.0 1.56 35.5 3200 435 380 600 500
300 3.0 2.2 34.5 3450 0.40 0.8 1.56 36.0 3600 2.0 1.56 38.0 3850 490 425 680 500

17
 WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF AN ISO 9001:2000
COMPANY

CABLES
400 3.3 2.2 38.5 4450 0.40 0.8 1.56 40.0 4650 2.0 1.72 42.5 4950 550 480 790 500
500 3.5 2.4 42.0 5500 0.50 0.8 1.72 43.5 5750 2.0 1.88 46.5 6050 610 530 910 500
630 3.5 2.4 45.5 6750 0.50 0.8 1.88 47.5 7100 2.0 1.88 50.0 7350 680 580 1030 500
800 3.5 2.6 50.0 8450 0.50 0.8 1.88 51.0 8700 2.5 2.04 55.0 9250 740 630 1140 500
1000 3.6 2.8 55.0 10450 0.60 0.8 2.04 56.5 10800 2.5 2.20 60.5 11350 790 670 1250 500

The above data is approximate and subject to manufacturing tolerance.

* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.
18
WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF AN ISO 9001:2000
COMPANY

CABLES TABLE 9 - 6.35/11 KV (E), 6.6/6.6 KV (UE) HT XLPE SINGLE CORE ALUMINIUM CONDUCTOR CABLES
“POLYCAB” SINGLE CORE ALUMINIUM CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES
CONFORMING TO IS: 7098 PART-2/1985:
UNARMOURED CABLE ALUMINIUM STRIP ARMOURED ALUMINIUM ROUND WIRE ARMOURED CURRENT CARRYING
Nomina
Nomina Minimu CABLE CABLE CAPACITY
l *Norm
l Nomin Approx. Approx m Nomin Minimu Approx Approx Nomin Minimu Approx Approx In In Duct In Air
Thicknes al
Size al Overall . Weight Thicknes al m . . Weight al m . . Weight Ground at 30° at
s of Thicknes Diaete of Deliver
of s of Dimesio Thicknes Overall of Dimesio Thicknes Overall of at C. 40°
XLPE y
Conducto s of r of Cable. Inner n of s of Diamete Cable. n of s of Diamete Cable. 30° C. C.
Insulatio PVC Cable. Length
r Sheath Strip PVC r of Roun PVC r of
n .
Outer Outer Cable. d Outer Cable.
Sheath Sheath Wire Sheath
Sq.mm mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
.
35 3.6 2.0 21.5 550 0.30 0.8 1.4 23.0 650 1.6 1.40 24.5 750 120 105 145 500
50 3.6 2.0 23.0 600 0.30 0.8 1.4 24.0 700 1.6 1.40 25.5 800 140 125 170 500
70 3.6 2.0 24.5 700 0.30 0.8 1.4 25.5 800 1.6 1.40 27.5 950 175 155 215 500
95 3.6 2.0 26.0 800 0.30 0.8 1.4 27.5 950 1.6 1.40 29.0 1050 205 180 260 500
120 3.6 2.0 28.0 950 0.30 0.8 1.4 29.0 1050 1.6 1.56 31.0 1200 235 205 305 500
150 3.6 2.0 29.0 1050 0.30 0.8 1.56 30.5 1200 1.6 1.56 32.5 1350 260 230 345 500
185 3.6 2.2 31.5 1250 0.40 0.8 1.56 33.0 1400 2.0 1.56 35.5 1600 295 260 395 500
240 3.6 2.2 35.0 1450 0.40 0.8 1.56 35.0 1600 2.0 1.56 38.0 1850 340 300 470 500
300 3.6 2.2 36.0 1650 0.40 0.8 1.56 37.0 1850 2.0 1.56 40.0 2100 385 335 540 500
400 3.6 2.2 39.0 2000 0.40 0.8 1.72 40.5 2250 2.0 1.72 43.5 2550 440 380 630 500
500 3.6 2.4 42.5 2450 0.50 0.8 1.72 44.0 2650 2.0 1.88 46.5 3000 495 430 730 500
630 3.6 2.4 46.0 2900 0.50 0.8 1.88 47.5 3200 2.0 1.88 50.0 3450 560 480 840 500
800 3.6 2.6 50.0 3500 0.50 0.8 1.88 51.5 3800 2.5 2.04 55.0 4300 620 530 960 500
1000 3.6 2.8 55.0 4250 0.60 0.8 2.04 56.5 4600 2.5 2.20 60.5 5150 680 580 1070 500

TABLE 10 - 6.35/11 KV (E), 6.6/6.6 KV (UE) HT XLPE SINGLE CORE COPPER CONDUCTOR CABLES
“POLYCAB” SINGLE CORE COPPER CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES CONFORMING
TO IS: 7098 PART-2/1985:
UNARMOURED CABLE ALUMINIUM STRIP ARMOURED ALUMINIUM ROUND WIRE ARMOURED CURRENT CARRYING
Nomina
Nomina Minimu CABLE CABLE CAPACITY
l *Norm
l Nomin Approx. Approx m Nomin Minimu Approx Approx Nomin Minimu Approx Approx In In Duct In Air
Thicknes al
Size al Overall . Weight Thicknes al m . . Weight al m . . Weight Ground at 30° at
s of Thicknes Diaete of Deliver
of s of Dimesio Thicknes Overall of Dimesio Thicknes Overall of at C. 40°
XLPE y
Conducto s of r of Cable. Inner n of s of Diamete Cable. n of s of Diamete Cable. 30° C. C.
Insulatio PVC Cable. Length
r Sheath Strip PVC r of Roun PVC r of
n .
Outer Outer Cable. d Outer Cable.
Sheath Sheath Wire Sheath
Sq.mm mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
.
35 3.6 2.0 21.5 750 0.30 0.8 1.4 23.0 850 1.6 1.40 24.5 950 155 140 185 500
50 3.6 2.0 23.0 900 0.30 0.8 1.4 24.0 1000 1.6 1.40 25.5 1110 185 160 220 500
70 3.6 2.0 24.5 1150 0.30 0.8 1.4 25.5 1250 1.6 1.40 27.5 1350 225 195 275 500
95 3.6 2.0 26.0 1400 0.30 0.8 1.4 27.5 1550 1.6 1.40 29.0 1650 265 235 340 500
120 3.6 2.0 28.0 1650 0.30 0.8 1.4 29.0 1800 1.6 1.56 31.0 1950 300 265 390 500
150 3.6 2.0 29.0 1950 0.30 0.8 1.56 30.5 2150 1.6 1.56 32.5 2250 335 295 440 500
185 3.6 2.2 31.5 2400 0.40 0.8 1.56 33.0 2550 2.0 1.56 35.5 2750 380 330 510 500
240 3.6 2.2 33.5 2900 0.40 0.8 1.56 35.0 3100 2.0 1.56 38.0 3350 435 380 600 500
The above data is approximate and subject to manufacturing tolerance.
* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.
17
 WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF AN ISO 9001:2000
COMPANY

CABLES
300 3.6 2.2 36.0 3500 0.40 0.8 1.56 37.0 3700 2.0 1.56 40.0 3950 490 425 680 500
400 3.6 2.2 39.0 4500 0.40 0.8 1.72 40.5 4750 2.0 1.72 43.5 5050 550 480 790 500
500 3.6 2.4 42.5 5500 0.50 0.8 1.72 44.0 5800 2.0 1.88 46.5 6100 610 530 910 250
630 3.6 2.4 46.0 6800 0.50 0.8 1.88 47.5 7100 2.0 1.88 50.0 7350 680 580 1030 250
800 3.6 2.6 50.0 8450 0.50 0.8 1.88 51.5 8750 2.5 2.04 55.0 9250 740 630 1140 250
1000 3.6 2.8 55.0 10450 0.60 0.8 2.04 56.5 10800 2.5 2.20 60.5 11350 790 670 1250 200

The above data is approximate and subject to manufacturing tolerance.

* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.
18
WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF AN ISO 9001:2000
COMPANY

CABLES TABLE 11 - 11/ 11 KV (UE) HT XLPE SINGLE CORE ALUMINIUM CONDUCTOR CABLES
“POLYCAB” SINGLE CORE ALUMINIUM CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES
CONFORMING TO IS: 7098 PART-2/1985:
UNARMOURED CABLE ALUMINIUM STRIP ARMOURED ALUMINIUM ROUND WIRE ARMOURED CURRENT CARRYING
Nomina
Nomina Minimu CABLE CABLE CAPACITY
l *Norm
l Nomin Approx. Approx m Nomin Minimu Approx Approx Nomin Minimu Approx Approx In In Duct In Air
Thicknes al
Size al Overall . Weight Thicknes al m . . Weight al m . . Weight Ground at 30° at
s of Thicknes Diaete of Deliver
of s of Dimesio Thicknes Overall of Dimesio Thicknes Overall of at C. 40°
XLPE y
Conducto s of r of Cable. Inner n of s of Diamete Cable. n of s of Diamete Cable. 30° C. C.
Insulatio PVC Cable. Length
r Sheath Strip PVC r of Roun PVC r of
n .
Outer Outer Cable. d Outer Cable.
Sheath Sheath Wire Sheath
Sq.mm mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
.
70 5.5 2.0 28.5 850 0.30 0.8 1.56 30.0 1050 1.6 1.56 31.5 1150 175 155 215 500
95 5.5 2.0 30.0 980 0.30 0.8 1.56 32.0 1200 2.0 1.56 34.0 1350 205 180 260 500
120 5.5 2.2 32.0 1150 0.40 0.8 1.56 33.5 1300 2.0 1.56 36.0 1500 235 205 305 500
150 5.5 2.2 33.5 1260 0.40 0.8 1.56 35.0 1450 2.0 1.56 37.0 1650 260 230 345 500
185 5.5 2.2 35.5 1430 0.40 0.8 1.56 37.0 1600 2.0 1.56 39.0 1850 295 260 395 500
240 5.5 2.2 37.5 1650 0.40 0.8 1.56 39.0 1850 2.0 1.72 42.0 2150 340 300 470 500
300 5.5 2.2 39.5 1900 0.40 0.8 1.72 41.5 2150 2.0 1.72 44.0 2400 385 335 540 500
400 5.5 2.4 43.0 2300 0.50 0.8 1.72 45.0 2600 2.0 1.88 47.5 2900 440 380 630 500
500 5.5 2.4 46.0 2700 0.50 0.8 1.88 48.0 3000 2.5 2.04 52.0 3500 495 430 730 500
630 5.5 2.6 50.0 3200 0.50 0.8 1.88 51.5 3500 2.5 2.04 55.0 4050 560 480 840 500
800 5.5 2.8 54.0 3880 0.60 0.8 2.04 56.0 4200 2.5 2.2 60.0 4800 620 530 960 500
1000 5.5 2.8 59.0 4600 0.60 0.8 2.2 61.0 5000 2.5 2.36 65.0 5650 680 580 1070 500

TABLE 12 - 11 / 11 KV (UE) HT XLPE SINGLE CORE COPPER CONDUCTOR CABLES

“POLYCAB” SINGLE CORE COPPER CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES CONFORMING TO IS:
7098 PART-2/1985:
UNARMOURED CABLE ALUMINIUM STRIP ARMOURED ALUMINIUM ROUND WIRE ARMOURED CURRENT CARRYING
Nomina
Nomina Minimu CABLE CABLE CAPACITY
l *Norm
l Nomin Approx. Approx m Nominal Minimu Approx Approx Nomina Minimu Approx Approx In In In Air
Thicknes al
Size al Overall . Weight Thicknes Dimesion m . . Weight l m . . Weight Ground Duct at
s of Thicknes Diaete of Deliver
of s of of Strip Thicknes Overall of Dimesio Thicknes Overall of at at 30° 40°
XLPE y
Conducto s of r of Cable. Inner s of Diamete Cable. n of s of Diamete Cable. 30° C. C. C.
Insulatio PVC Cable. Length
r Sheath PVC r of Round PVC r of
n .
Outer Outer Cable. Wire Outer Cable.
Sheath Sheath Sheath
Sq.mm. mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
70 5.5 2.0 28.5 1300 0.30 0.8 1.56 30.0 1500 1.6 1.56 31.5 1600 225 195 275 500
95 5.5 2.0 30.0 1550 0.30 0.8 1.56 32.0 1800 2.0 1.56 34.0 1950 265 235 340 500
120 5.5 2.2 32.0 1900 0.40 0.8 1.56 33.5 2050 2.0 1.56 36.0 2250 300 265 390 500
150 5.5 2.2 33.5 2200 0.40 0.8 1.56 35.0 2400 2.0 1.56 37.0 2600 335 295 440 500
185 5.5 2.2 35.5 2600 0.40 0.8 1.56 37.0 2750 2.0 1.56 39.0 3000 380 330 510 500
240 5.5 2.2 37.5 3150 0.40 0.8 1.56 39.0 3350 2.0 1.72 42.0 3650 435 380 600 500
300 5.5 2.2 39.5 3750 0.40 0.8 1.72 41.5 4000 2.0 1.72 44.0 4250 490 425 680 500
400 5.5 2.4 43.0 4800 0.50 0.8 1.72 45.0 5100 2.0 1.88 47.5 5400 550 480 790 500

The above data is approximate and subject to manufacturing tolerance.

* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.
19
 WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF AN ISO 9001:2000
COMPANY

CABLES
500 5.5 2.4 46.0 5800 0.50 0.8 1.88 48.0 6100 2.5 2.04 52.0 6600 610 530 910 500
630 5.5 2.6 50.0 7100 0.50 0.8 1.88 51.5 7400 2.5 2.04 55.0 7950 680 580 1030 500
800 5.5 2.8 54.0 8850 0.60 0.8 2.04 56.0 9150 2.5 2.2 60.0 9750 740 630 1140 500
1000 5.5 2.8 59.0 10800 0.60 0.8 2.2 61.0 11200 2.5 2.36 65.0 11850 790 670 1250 500

The above data is approximate and subject to manufacturing tolerance.

* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.
20
WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF AN ISO 9001:2000
COMPANY

CABLES TABLE 13 - 12.7/22 KV (E) HT XLPE SINGLE CORE ALUMINIUM CONDUCTOR CABLES
“POLYCAB” SINGLE CORE ALUMINIUM CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES
CONFORMING TO IS: 7098 PART-2/1985:
UNARMOURED CABLE ALUMINIUM STRIP ARMOURED ALUMINIUM ROUND WIRE ARMOURED CURRENT CARRYING
Nomina
Nomina Minimu CABLE CABLE CAPACITY
l *Norm
l Nomin Approx. Approx m Nomin Minimu Approx Approx Nomin Minimu Approx Approx In In Duct In Air
Thicknes al
Size al Overall . Weight Thicknes al m . . Weight al m . . Weight Ground at 30° at
s of Thicknes Diaete of Deliver
of s of Dimesio Thicknes Overall of Dimesio Thicknes Overall of at C. 40°
XLPE y
Conducto s of r of Cable. Inner n of s of Diamete Cable. n of s of Diamete Cable. 30° C. C.
Insulatio PVC Cable. Length
r Sheath Strip PVC r of Roun PVC r of
n .
Outer Outer Cable. d Outer Cable.
Sheath Sheath Wire Sheath
Sq.mm mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
.
95 6.0 2.2 32.0 1100 0.40 0.8 1.56 33.0 1250 2.0 1.56 36.0 1450 205 180 270 500
120 6.0 2.2 34.0 1200 0.40 0.8 1.56 35.0 1400 2.0 1.56 37.5 1600 230 200 310 500
150 6.0 2.2 35.0 1350 0.40 0.8 1.56 36.0 1530 2.0 1.56 39.0 1750 260 225 350 500
185 6.0 2.2 37.0 1500 0.40 0.8 1.56 38.0 1700 2.0 1.72 41.0 2000 290 255 400 500
240 6.0 2.2 39.0 1750 0.40 0.8 1.56 40.5 1950 2.0 1.72 43.0 2250 335 290 470 500
300 6.0 2.2 41.0 2000 0.40 0.8 1.72 43.0 2250 2.0 1.72 45.0 2500 380 325 540 500
400 6.0 2.4 45.0 2400 0.50 0.8 1.88 47.0 2700 2.0 1.88 49.0 3000 430 370 630 500
500 6.0 2.6 48.0 2850 0.50 0.8 1.88 50.0 3100 2.5 2.04 53.5 3650 485 420 730 500
630 6.0 2.6 51.5 3300 0.50 0.8 2.04 54.0 3700 2.5 2.04 57.0 4150 550 470 840 500
800 6.0 2.8 56.0 4000 0.60 0.8 2.04 58.0 4350 2.5 2.2 61.0 5000 610 520 950 500
1000 6.0 3.0 61.0 4800 0.60 0.8 2.2 62.5 5150 2.5 2.36 66.0 5800 660 560 1060 500

TABLE 14 - 12.7 / 22 KV (E) HT XLPE SINGLE CORE COPPER CONDUCTOR CABLES

“POLYCAB” SINGLE CORE COPPER CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES CONFORMING TO IS:
7098 PART-2/1985:
UNARMOURED CABLE ALUMINIUM STRIP ARMOURED ALUMINIUM ROUND WIRE ARMOURED CURRENT CARRYING
Nomina
Nomina Minimu CABLE CABLE CAPACITY
l *Norm
l Nomin Approx. Approx m Nomin Minimu Approx Approx Nomin Minimu Approx Approx In In Duct In Air
Thicknes al
Size al Overall . Weight Thicknes al m . . Weight al m . . Weight Ground at 30° at
s of Thicknes Diaete of Deliver
of s of Dimesio Thicknes Overall of Dimesio Thicknes Overall of at C. 40°
XLPE y
Conducto s of r of Cable. Inner n of s of Diamete Cable. n of s of Diamete Cable. 30° C. C.
Insulatio PVC Cable. Length
r Sheath Strip PVC r of Roun PVC r of
n .
Outer Outer Cable. d Outer Cable.
Sheath Sheath Wire Sheath
Sq.mm mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
.
95 6.0 2.2 32.0 1650 0.40 0.8 1.56 33.0 1850 2.0 1.56 36.0 2050 265 230 345 500
120 6.0 2.2 34.0 1950 0.40 0.8 1.56 35.0 2150 2.0 1.56 37.5 2350 300 260 400 500
150 6.0 2.2 35.0 2250 0.40 0.8 1.56 36.0 2450 2.0 1.56 39.0 2700 330 290 450 500
185 6.0 2.2 37.0 2650 0.40 0.8 1.56 38.0 2850 2.0 1.72 41.0 3150 375 325 510 500
240 6.0 2.2 39.0 3200 0.40 0.8 1.56 40.5 3450 2.0 1.72 43.0 3750 430 370 600 500
300 6.0 2.2 41.0 3850 0.40 0.8 1.72 43.0 4100 2.0 1.72 45.0 4350 480 415 690 500
400 6.0 2.4 45.0 4900 0.50 0.8 1.88 47.0 5200 2.0 1.88 49.0 5500 540 465 790 500

The above data is approximate and subject to manufacturing tolerance.

* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.
21
 WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF AN ISO 9001:2000
COMPANY

CABLES
500 6.0 2.6 48.0 5950 0.50 0.8 1.88 50.0 6200 2.5 2.04 53.5 6750 600 520 910 250
630 6.0 2.6 51.5 7200 0.50 0.8 2.04 54.0 7600 2.5 2.04 57.0 8050 660 570 1020 250
800 6.0 2.8 56.0 8950 0.60 0.8 2.04 58.0 9300 2.5 2.2 61.0 9900 720 620 1140 250
1000 6.0 3.0 61.0 11000 0.60 0.8 2.2 62.5 11350 2.5 2.36 66.0 12000 760 660 1240 200

The above data is approximate and subject to manufacturing tolerance.

* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.
22
WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF AN ISO 9001:2000
COMPANY

CABLES TABLE 15 - 19 / 33 KV (E) HT XLPE SINGLE CORE ALUMINIUM CONDUCTOR CABLES

“POLYCAB” SINGLE CORE ALUMINIUM CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES CONFORMING
TO IS: 7098 PART-2/1985:
UNARMOURED CABLE ALUMINIUM STRIP ARMOURED ALUMINIUM ROUND WIRE ARMOURED CURRENT CARRYING
Nomina
Nomina Minimu CABLE CABLE CAPACITY
l *Norm
l Nomin Approx. Approx m Nomin Minimu Approx Approx Nomin Minimu Approx Approx In In Duct In Air
Thicknes al
Size al Overall . Weight Thicknes al m . . Weight al m . . Weight Ground at 30° at
s of Thicknes Diaete of Deliver
of s of Dimesio Thicknes Overall of Dimesio Thicknes Overall of at C. 40°
XLPE y
Conducto s of r of Cable. Inner n of s of Diamete Cable. n of s of Diamete Cable. 30° C. C.
Insulatio PVC Cable. Length
r Sheath Strip PVC r of Roun PVC r of
n .
Outer Outer Cable. d Outer Cable.
Sheath Sheath Wire Sheath
Sq.mm mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
.
95 8.8 2.2 37.5 1400 0.40 0.8 1.56 39.0 1600 2.0 1.72 41.5 1900 200 180 270 500
120 8.8 2.2 39.0 1550 0.40 0.8 1.72 41.0 1800 2.0 1.72 43.0 2050 230 200 310 500
150 8.8 2.2 40.0 1700 0.40 0.8 1.72 42.0 1950 2.0 1.72 44.5 2200 260 225 350 500
185 8.8 2.4 43.0 1900 0.50 0.8 1.72 44.5 2200 2.0 1.88 47.0 2500 290 255 400 500
240 8.8 2.4 45.0 2200 0.50 0.8 1.88 47.0 2500 2.0 1.88 49.5 2760 335 290 470 500
300 8.8 2.6 48.0 2500 0.50 0.8 1.88 49.0 2750 2.0 2.04 52.0 3100 380 325 540 500
400 8.8 2.6 51.0 2900 0.50 0.8 2.04 52.5 3250 2.0 2.04 55.0 3550 430 370 630 500
500 8.8 2.8 54.0 3400 0.60 0.8 2.04 56.0 3700 2.5 2.2 60.0 4250 485 420 730 500
630 8.8 2.8 57.5 3900 0.60 0.8 2.2 60.0 4300 2.5 2.36 63.0 4900 550 470 840 500
800 8.8 3.0 62.0 4600 0.60 0.8 2.36 64.0 5050 2.5 2.36 67.0 5600 610 520 950 500
1000 8.8 3.2 67.0 5450 0.70 0.8 2.36 69.0 5900 2.5 2.52 72.5 6550 660 560 1060 500

TABLE 16 - 19 / 33 KV (E) HT XLPE SINGLE CORE COPPER CONDUCTOR CABLES

“POLYCAB” SINGLE CORE COPPER CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES CONFORMING TO IS:
7098 PART-2/1985:
UNARMOURED CABLE ALUMINIUM STRIP ARMOURED ALUMINIUM ROUND WIRE ARMOURED CURRENT CARRYING *Norm
Nomina Minimu CABLE CABLE CAPACITY al
Nomin Deliver
l Nomin Approx Approx m Nominal Minimu Approx Approx Nomina Minimu Approx Approx In In In Air
al Size y
Thicknes al . . Weight Thicknes Dimensio m . . Weight l m . . Weight Groun Duct at
of Length
s of Thicknes Overall of s of n of Thicknes Overall of Dimensio Thicknes Overall of d at at 30° 40°
Conducto .
XLPE s of Diamete Cable. Inner Strip s of Diamete Cable. n of s of Diamete Cable. 30° C. C. C.
r
Insulatio PVC r of Sheath PVC r of Round PVC r of
n Outer Cable. Outer Cable. Wire Outer Cable.
Sheath Sheath Sheath
Sq.mm. mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
95 8.8 2.2 37.5 2000 0.40 0.8 1.56 39.0 2200 2.0 1.72 41.5 2550 265 230 345 500
120 8.8 2.2 39.0 2300 0.40 0.8 1.72 41.0 2550 2.0 1.72 43.0 2800 300 260 400 500
150 8.8 2.2 40.0 2600 0.40 0.8 1.72 42.0 2850 2.0 1.72 44.5 3100 330 290 450 500
185 8.8 2.4 43.0 3050 0.50 0.8 1.72 44.5 3300 2.0 1.88 47.0 3650 375 325 510 500
240 8.8 2.4 45.0 3650 0.50 0.8 1.88 47.0 4000 2.0 1.88 49.5 4250 430 370 600 500
300 8.8 2.6 48.0 4350 0.50 0.8 1.88 49.0 4600 2.0 2.04 52.0 4950 480 415 690 500
400 8.8 2.6 51.0 5350 0.50 0.8 2.04 52.5 5700 2.0 2.04 55.0 6050 540 465 790 250
500 8.8 2.8 54.0 6450 0.60 0.8 2.04 56.0 6800 2.5 2.2 60.0 7350 600 520 910 250

The above data is approximate and subject to manufacturing tolerance.

* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.
23
 WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF AN ISO 9001:2000
COMPANY

CABLES
630 8.8 2.8 57.5 7000 0.60 0.8 2.2 60.0 8200 2.5 2.36 63.0 8800 660 570 1020 250
800 8.8 3.0 62.0 9550 0.60 0.8 2.36 64.0 10000 2.5 2.36 67.0 10600 720 620 1140 250
1000 8.8 3.2 67.0 11600 0.70 0.8 2.36 69.0 12100 2.5 2.52 72.5 12750 760 660 1240 200

The above data is approximate and subject to manufacturing tolerance.

* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.
24
WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF AN ISO 9001:2000
COMPANY

CABLES TABLE 17 - 33 / 33 KV (UE) HT XLPE SINGLE CORE ALUMINIUM CONDUCTOR CABLE

“POLYCAB” SINGLE CORE ALUMINIUM CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES
CONFORMING TO IS: 7098 PART-2/1985:
UNARMOURED CABLE ALUMINIUM STRIP ARMOURED ALUMINIUM ROUND WIRE ARMOURED CURRENT CARRYING
Nomina Nomina Minimu CABLE CABLE CAPACITY
l *Norm
l Nomin Approx. Approx m Nomin Minimu Approx Approx Nomin Minimu Approx Approx In In Duct In Air
al
Size Thicknes al Overall . Weight Thicknes al m . . Weight al m . . Weight Ground at 30° at
s of Thicknes Diaete of Deliver
of s of Dimesio Thicknes Overall of Dimesio Thicknes Overall of at C. 40°
y
Conducto XLPE s of r of Cable. Inner n of s of Diamete Cable. n of s of Diamete Cable. 30° C. C.
Insulatio PVC Cable. Length
r Sheath Strip PVC r of Roun PVC r of
n .
Outer Outer Cable. d Outer Cable.
Sheath Sheath Wire Sheath
Sq.mm mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
.
120 9.5 2.2 41.5 1700 0.40 0.8 1.72 43.0 2000 2.0 1.72 45.5 2250 230 200 310 500
150 9.5 2.4 43.0 1900 0.40 0.8 1.72 44.5 2150 2.0 1.88 47.5 2500 260 225 350 500
185 9.5 2.4 45.0 2100 0.50 0.8 1.72 46.5 2400 2.0 1.88 49.5 2700 290 255 400 500
240 9.5 2.4 47.5 2350 0.50 0.8 1.88 49.5 2700 2.5 2.04 53.0 3200 335 290 470 500
300 9.5 2.6 50.0 2650 0.50 0.8 1.88 51.5 3000 2.5 2.04 55.0 3500 380 325 540 500
400 9.5 2.6 53.0 3100 0.50 0.8 2.04 55.0 3450 2.5 2.2 58.5 4000 430 370 630 500
500 9.5 2.8 56.5 3600 0.60 0.8 2.04 58.0 3950 2.5 2.2 62.0 4550 485 420 730 500
630 9.5 3.0 60.0 4200 0.60 0.8 2.2 61.5 4550 2.5 2.36 65.5 5200 550 470 840 500
800 9.5 3.0 64.0 4850 0.60 0.8 2.36 66.0 5300 3.15 2.52 71.0 6200 610 520 950 500
1000 9.5 3.2 69.0 5700 0.70 0.8 2.52 71.0 6250 3.15 2.68 76.0 7250 660 560 1060 500

TABLE 18 - 33 / 33 KV (UE) HT XLPE SINGLE CORE COPPER CONDUCTOR CABLE

“POLYCAB” SINGLE CORE COPPER CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES CONFORMING TO IS:
7098 PART-2/1985:
UNARMOURED CABLE ALUMINIUM STRIP ARMOURED ALUMINIUM ROUND WIRE ARMOURED CURRENT CARRYING
Nomina
Nomina Minimu CABLE CABLE CAPACITY
l *Norm
l Nomin Approx. Approx m Nomin Minimu Approx Approx Nomin Minimu Approx Approx In In Duct In Air
Thicknes al
Size al Overall . Weight Thicknes al m . . Weight al m . . Weight Ground at 30° at
s of Thicknes Diaete of Deliver
of s of Dimesio Thicknes Overall of Dimesio Thicknes Overall of at C. 40°
XLPE y
Conducto s of r of Cable. Inner n of s of Diamete Cable. n of s of Diamete Cable. 30° C. C.
Insulatio PVC Cable. Length
r Sheath Strip PVC r of Roun PVC r of
n .
Outer Outer Cable. d Outer Cable.
Sheath Sheath Wire Sheath
Sq.mm mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
.
120 9.5 2.2 41.5 2450 0.40 0.8 1.72 43.0 2750 2.0 1.72 45.5 3000 300 260 400 500
150 9.5 2.4 43.0 2850 0.40 0.8 1.72 44.5 3050 2.0 1.88 47.5 3400 330 290 450 500
185 9.5 2.4 45.0 3250 0.50 0.8 1.72 46.5 3500 2.0 1.88 49.5 3850 375 325 510 500
240 9.5 2.4 47.5 3850 0.50 0.8 1.88 49.5 4200 2.5 2.04 53.0 4650 430 370 600 500
300 9.5 2.6 50.0 4550 0.50 0.8 1.88 51.5 4850 2.5 2.04 55.0 5350 480 415 690 500
400 9.5 2.6 53.0 5600 0.50 0.8 2.04 55.0 5950 2.5 2.2 58.5 6500 540 465 790 250
500 9.5 2.8 56.5 6700 0.60 0.8 2.04 58.0 7050 2.5 2.2 62.0 7650 600 520 910 250

The above data is approximate and subject to manufacturing tolerance.

* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.
25
 WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF AN ISO 9001:2000
COMPANY

CABLES
630 9.5 3.0 60.0 8100 0.60 0.8 2.2 61.5 8450 2.5 2.36 65.5 9100 660 570 1020 250
800 9.5 3.0 64.0 9800 0.60 0.8 2.36 66.0 10250 3.15 2.52 71.0 11200 720 620 1140 250
1000 9.5 3.2 69.0 11900 0.70 0.8 2.52 71.0 12450 3.15 2.68 76.0 13450 760 660 1240 200

The above data is approximate and subject to manufacturing tolerance.

* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.
26
WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF AN ISO 9001:2000
COMPANY

CABLES TABLE 19 - 1.9/3.3 KV (E) & 3.3/3.3 KV (UE) HT XLPE THREE CORE ALUMINIUM CONDUCTOR CABLES
“POLYCAB” THREE CORE ALUMINIUM CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED SCREENED CABLES
CONFORMING TO IS: 7098 PART-2/1985:
UNARMOURED CABLE FORMED WIRE / STRIP ARMOURED ROUND WIRE ARMOURED CABLE CURRENT CARRYING
Minimu CABLE CAPACITY
Nomina
Nomina
m *Norm
l l Nomon Approx Appro Nominal Minimu Approx Approx Nominal Minimu Approx Approx In In Duct In Air
Thicknes al
Size
Thicknes al . x Dimensio m . . Weight Dimensio m . . Weight Ground at 30° at
s of Deliver
of s of Thicknes Overall Weigh n of GI Thicknes Overall of n of GI Thicknes Overall of at C. 40°
PVC y
ConductoXLPE s of Diamete t of Flat s of Diamete Cable. Round s of Diamete Cable. 30° C. C.
Inner Length
r Insulatio PVC r of Cable Strip PVC r of Wire PVC r of
Sheath .
n Outer Cable. Outer Cable. Outer Cable.
Sheath Sheath Sheath
Sq.mm mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
.
35 2.2 0.4 2.2 38.0 1500 0.8 1.56 37.0 1950 2.0 1.72 40.5 2600 115 97 125 500
50 2.2 0.4 2.2 40.0 1700 0.8 1.72 39.5 2200 2.0 1.72 42.5 2900 130 115 150 500
70 2.2 0.5 2.4 44.5 2150 0.8 1.72 44.0 2650 2.0 1.88 47.0 3450 160 140 190 500
95 2.2 0.5 2.6 48.5 2600 0.8 1.88 47.5 3150 2.5 2.04 51.5 4400 190 165 230 500
120 2.2 0.5 2.6 52.0 3000 0.8 2.04 51.5 3650 2.5 2.04 55.5 5000 220 190 260 500
150 2.2 0.6 2.8 55.5 3500 0.8 2.04 54.5 4100 2.5 2.2 58.5 5550 245 210 295 500
185 2.2 0.6 3.0 60.0 4150 0.8 2.2 59.0 4800 2.5 2.36 63.0 6350 275 240 335 500
240 2.2 0.7 3.0 65.0 4900 0.8 2.36 64.5 5750 2.5 2.36 68.0 7350 315 275 395 500
300 2.2 0.7 3.2 70.0 5850 0.8 2.52 70.0 6650 3.15 2.68 75.0 9250 355 310 450 500
400 2.2 0.7 3.6 78.0 7300 0.8 2.68 76.5 8100 3.15 2.84 82.0 11000 400 350 520 500

TABLE 20 - 1.9/3.3 KV (E) & 3.3/3.3 (UE) KV HT XLPE THREE CORE COPPER CONDUCTOR CABLES
“POLYCAB” THREE CORE COPPER CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED SCREENED CABLES
CONFORMING TO IS: 7098 PART-2/1985:
UNARMOURED CABLE FORMED WIRE / STRIP ARMOURED ROUND WIRE ARMOURED CABLE CURRENT CARRYING
Minimu CABLE CAPACITY
Nomina
Nomina
m *Norm
l l Nomon Approx Appro Nominal Minimu Approx Approx Nominal Minimu Approx Approx In In Duct In Air
Thicknes al
Size
Thicknes al . x Dimensio m . . Weight Dimensio m . . Weight Ground at 30° at
s of Deliver
of s of Thicknes Overall Weigh n of GI Thicknes Overall of n of GI Thicknes Overall of at C. 40°
PVC y
ConductoXLPE s of Diamete t of Flat s of Diamete Cable. Round s of Diamete Cable. 30° C. C.
Inner Length
r Insulatio PVC r of Cable Strip PVC r of Wire PVC r of
Sheath .
n Outer Cable. Outer Cable. Outer Cable.
Sheath Sheath Sheath
Sq.mm mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
.
35 2.2 0.4 2.2 38.0 2150 0.8 1.56 37.0 2600 2.0 1.72 40.5 3250 145 125 165 500
50 2.2 0.4 2.2 40.0 2650 0.8 1.72 39.5 3150 2.0 1.72 42.5 3800 170 150 195 500
70 2.2 0.5 2.4 44.5 3450 0.8 1.72 44.0 3950 2.0 1.88 47.0 4750 210 180 240 500
95 2.2 0.5 2.6 48.5 4350 0.8 1.88 47.5 4950 2.5 2.04 51.5 6150 250 215 295 500
120 2.2 0.5 2.6 52.0 5250 0.8 2.04 51.5 5900 2.5 2.04 55.5 7200 280 240 335 500
150 2.2 0.6 2.8 55.5 6300 0.8 2.04 54.5 6900 2.5 2.2 58.5 8350 310 270 380 500
The above data is approximate and subject to manufacturing tolerance.
* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.
27
 WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF AN ISO 9001:2000
COMPANY

CABLES
185 2.2 0.6 3.0 60.0 7600 0.8 2.2 59.0 8250 2.5 2.36 63.0 9800 350 305 430 500
240 2.2 0.7 3.0 65.0 9350 0.8 2.36 64.5 10250 2.5 2.36 68.0 11800 400 350 500 500
300 2.2 0.7 3.2 70.0 11400 0.8 2.52 70.0 12250 3.15 2.68 75.0 14850 445 390 510 500
400 2.2 0.7 3.6 78.0 14750 0.8 2.68 76.5 15550 3.15 2.84 82.0 18450 500 440 650 250

The above data is approximate and subject to manufacturing tolerance.

* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.
28
WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF AN ISO 9001:2000
COMPANY

CABLES TABLE 21 - 3.8 / 6.6 KV (E) HT XLPE THREE CORE ALUMINIUM CONDUCTOR CABLES
“POLYCAB”THREE CORE ALUMINIUM CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES CONFORMING
TO IS: 7098 PART-2/1985:
UNARMOURED CABLE FORMED WIRE / STRIP ARMOURED ROUND WIRE ARMOURED CABLE CURRENT CARRYING
Minimu CABLE CAPACITY
Nomina
Nomina
m *Norm
l l Nomon Approx Appro Nominal Minimu Approx Approx Nominal Minimu Approx Approx In In Duct In Air
Thicknes al
Size
Thicknes al . x Dimensio m . . Weight Dimensio m . . Weight Ground at 30° at
s of Deliver
of s of Thicknes Overall Weigh n of GI Thicknes Overall of n of GI Thicknes Overall of at C. 40°
PVC y
ConductoXLPE s of Diamete t of Flat s of Diamete Cable. Round s of Diamete Cable. 30° C. C.
Inner Length
r Insulatio PVC r of Cable Strip PVC r of Wire PVC r of
Sheath .
n Outer Cable. Outer Cable. Outer Cable.
Sheath Sheath Sheath
Sq.mm mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
.
35 2.8 0.4 2.2 40.0 1600 0.8 1.72 40.0 2200 2.0 1.72 43.0 2800 115 97 125 500
50 2.8 0.5 2.4 43.0 1950 0.8 1.72 42.5 2500 2.0 1.88 45.5 3200 130 115 150 500
70 2.8 0.5 2.6 47.0 2350 0.8 1.88 47.0 3000 2.0 1.88 49.5 3700 160 140 190 500
95 2.8 0.5 2.6 51.0 2800 0.8 1.88 50.5 3400 2.5 2.04 54.0 4700 190 165 230 500
120 2.8 0.6 2.8 55.0 3300 0.8 2.04 55.0 4000 2.5 2.20 58.5 5400 220 190 260 500
150 2.8 0.6 3.0 58.0 3800 0.8 2.2 58.0 4500 2.5 2.2 61.0 5900 245 210 295 500
185 2.8 0.6 3.2 63.0 4400 0.8 2.2 62.0 5150 2.5 2.36 66.0 6700 275 240 335 500
240 2.8 0.7 3.4 68.0 5300 0.8 2.36 67.5 6100 3.15 2.52 73.0 8600 315 275 395 500
300 3.0 0.7 3.6 74.0 6300 0.8 2.52 73.5 7160 3.15 2.68 78.5 9900 355 310 450 250
400 3.3 0.7 3.8 83.0 8000 0.8 2.84 82.0 9000 4.0 3.0 89.0 13200 400 350 520 250

TABLE 22 - 3.8/6.6 KV (E) HT XLPE THREE CORE COPPER CONDUCTOR CABLES

“POLYCAB” THREE CORE COPPER CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES CONFORMING TO IS:
7098 PART-2/1985:
UNARMOURED CABLE FORMED WIRE / STRIP ARMOURED ROUND WIRE ARMOURED CABLE CURRENT CARRYING
Minimu CABLE CAPACITY
Nomina Nomina
m *Norm
l l Nomon Approx Appro Nominal Minimu Approx Approx Nominal Minimu Approx Approx In In In Air
Thicknes al
Size Thicknes al . x Dimensio m . . Weight Dimensio m . . Weight Ground Duct at
s of Deliver
of s of Thicknes Overall Weigh n of GI Thicknes Overall of n of GI Thicknes Overall of at at 30° 40°
PVC y
Conducto XLPE s of Diamete t of Flat s of Diamete Cable. Round s of Diamete Cable. 30° C. C. C.
Inner Length
r Insulatio PVC r of Cable Strip PVC r of Wire PVC r of
Sheath .
n Outer Cable. Outer Cable. Outer Cable.
Sheath Sheath Sheath
Sq.mm. mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
35 2.8 0.4 2.2 40.0 2250 0.8 1.72 40.0 2850 2.0 1.72 43.0 3450 145 125 165 500
50 2.8 0.5 2.4 43.0 2850 0.8 1.72 42.5 3400 2.0 1.88 45.5 4150 170 150 195 500
70 2.8 0.5 2.6 47.0 3650 0.8 1.88 47.0 4250 2.0 1.88 49.5 5000 210 180 240 500
95 2.8 0.5 2.6 51.0 4550 0.8 1.88 50.5 5200 2.5 2.04 54.0 6500 250 215 295 500
120 2.8 0.6 2.8 55.0 5500 0.8 2.04 55.0 6200 2.5 2.20 58.5 7600 280 240 335 500
150 2.8 0.6 3.0 58.0 6550 0.8 2.2 58.0 7250 2.5 2.2 61.0 8700 310 270 380 500
185 2.8 0.6 3.2 63.0 7850 0.8 2.2 62.0 8600 2.5 2.36 66.0 10150 350 305 430 500

The above data is approximate and subject to manufacturing tolerance.

* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.
29
 WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF AN ISO 9001:2000
COMPANY

CABLES
240 2.8 0.7 3.4 68.0 9800 0.8 2.36 67.5 10550 3.15 2.52 73.0 13050 400 350 500 500
300 3.0 0.7 3.6 74.0 11900 0.8 2.52 73.5 12750 3.15 2.68 78.5 15450 445 390 570 250
400 3.3 0.7 3.8 83.0 15400 0.8 2.84 82.0 16400 4.0 3.0 89.0 20650 500 440 650 200

The above data is approximate and subject to manufacturing tolerance.

* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.
30
 WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF AN ISO 9001:2000
COMPANY

CABLES TABLE 23 - 6.35 / 11 KV (E) HT XLPE THREE CORE ALUMINIUM CONDUCTOR CABLES
“POLYCAB”THREE CORE ALUMINIUM CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES CONFORMING
TO IS: 7098 PART-2/1985:
UNARMOURED CABLE FORMED WIRE / STRIP ARMOURED ROUND WIRE ARMOURED CABLE CURRENT CARRYING
Minimu CABLE CAPACITY
Nomina
Nomina
m *Norm
l l Nomon Approx Appro Nominal Minimu Approx Approx Nominal Minimu Approx Approx In In Duct In Air
Thicknes al
Size
Thicknes al . x Dimensio m . . Weight Dimensio m . . Weight Ground at 30° at
s of Deliver
of s of Thicknes Overall Weigh n of GI Thicknes Overall of n of GI Thicknes Overall of at C. 40°
PVC y
ConductoXLPE s of Diamete t of Flat s of Diamete Cable. Round s of Diamete Cable. 30° C. C.
Inner Length
r Insulatio PVC r of Cable Strip PVC r of Wire PVC r of
Sheath .
n Outer Cable. Outer Cable. Outer Cable.
Sheath Sheath Sheath
Sq.mm mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
.
35 3.6 0.5 2.4 42.5 1950 0.8 1.72 42.5 2500 2.0 1.88 45.5 3250 115 97 125 500
50 3.6 0.5 2.6 46.0 2250 0.8 1.88 46.0 2850 2.5 2.04 49.5 4000 130 115 150 500
70 3.6 0.5 2.6 48.5 2650 0.8 1.88 49.0 3300 2.5 2.04 52.5 4600 160 140 190 500
95 3.6 0.6 2.8 53.0 3150 0.8 2.04 53.0 3850 2.5 2.20 56.5 5250 190 165 230 500
120 3.6 0.6 2.8 56.0 3600 0.8 2.2 56.0 4400 2.5 2.20 59.5 5850 220 190 260 500
150 3.6 0.6 3.0 59.0 4100 0.8 2.2 59.0 4900 2.5 2.36 63.0 6450 245 210 295 500
185 3.6 0.7 3.2 63.0 4850 0.8 2.36 63.0 5650 3.15 2.52 68.0 8100 275 240 335 500
240 3.6 0.7 3.4 68.0 5700 0.8 2.52 68.0 6600 3.15 2.68 73.0 9250 315 275 395 500
300 3.6 0.7 3.6 73.0 6650 0.8 2.68 73.0 7600 3.15 2.84 78.0 10400 355 310 450 250
400 3.6 0.7 3.8 80.0 8100 0.8 2.84 80.0 9100 4.0 3.0 86.5 13450 400 350 520 250

TABLE 24 - 6.35 / 11 KV (E) HT XLPE THREE CORE COPPER CONDUCTOR CABLES

“POLYCAB” THREE CORE COPPER CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES CONFORMING TO IS:
7098 PART-2/1985:
UNARMOURED CABLE FORMED WIRE / STRIP ARMOURED ROUND WIRE ARMOURED CABLE CURRENT CARRYING
Minimu CABLE CAPACITY
Nomina
Nomina
m *Norm
l l Nomon Approx Appro Nominal Minimu Approx Approx Nominal Minimu Approx Approx In In Duct In Air
Thicknes al
Size
Thicknes al . x Dimensio m . . Weight Dimensio m . . Weight Ground at 30° at
s of Deliver
of s of Thicknes Overall Weigh n of GI Thicknes Overall of n of GI Thicknes Overall of at C. 40°
PVC y
ConductoXLPE s of Diamete t of Flat s of Diamete Cable. Round s of Diamete Cable. 30° C. C.
Inner Length
r Insulatio PVC r of Cable Strip PVC r of Wire PVC r of
Sheath .
n Outer Cable. Outer Cable. Outer Cable.
Sheath Sheath Sheath
Sq.mm mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
.
35 3.6 0.5 2.4 42.5 2600 0.8 1.72 42.5 3150 2.0 1.88 45.5 3900 145 125 165 500
50 3.6 0.5 2.6 46.0 3150 0.8 1.88 46.0 3750 2.5 2.04 49.5 4950 170 150 195 500
70 3.6 0.5 2.6 48.5 3950 0.8 1.88 49.0 4600 2.5 2.04 52.5 5900 210 180 240 500
95 3.6 0.6 2.8 53.0 4950 0.8 2.04 53.0 5600 2.5 2.20 56.5 7000 250 215 295 500
120 3.6 0.6 2.8 56.0 5850 0.8 2.2 56.0 6650 2.5 2.20 59.5 8100 280 240 335 500
150 3.6 0.6 3.0 59.0 6900 0.8 2.2 59.0 7650 2.5 2.36 63.0 9250 310 270 380 500
185 3.6 0.7 3.2 63.0 8300 0.8 2.36 63.0 9100 3.15 2.52 68.0 11550 350 305 430 500
The above data is approximate and subject to manufacturing tolerance.
* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.
24
WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF AN ISO 9001:2000
COMPANY

CABLES
240 3.6 0.7 3.4 68.0 10200 0.8 2.52 68.0 11050 3.15 2.68 73.0 13700 400 350 500 250
300 3.6 0.7 3.6 73.0 12200 0.8 2.68 73.0 13150 3.15 2.84 78.0 15950 445 390 570 250
400 3.6 0.7 3.8 80.0 15550 0.8 2.84 80.0 16550 4.0 3.0 86.5 20900 500 440 650 250

The above data is approximate and subject to manufacturing tolerance.

* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.
25
 WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF AN ISO 9001:2000
COMPANY

CABLES TABLE 23
25 - 6.35 / 11KV
11 / 11 KV(UE)
(E) HT XLPE THREE CORE ALUMINIUM CONDUCTOR CABLES
“POLYCAB”THREE CORE ALUMINIUM CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES CONFORMING
TO IS: 7098 PART-2/1985:
UNARMOURED CABLE FORMED WIRE / STRIP ARMOURED ROUND WIRE ARMOURED CABLE CURRENT CARRYING
Minimu CABLE CAPACITY
Nomina
Nomina
m *Norm
l l Nomon Approx Appro Nominal Minimu Approx Approx Nominal Minimu Approx Approx In In Duct In Air
Thicknes al
Size
Thicknes al . x Dimensio m . . Weight Dimensio m . . Weight Ground at 30° at
s of Deliver
of s of Thicknes Overall Weigh n of GI Thicknes Overall of n of GI Thicknes Overall of at C. 40°
PVC y
ConductoXLPE s of Diamete t of Flat s of Diamete Cable. Round s of Diamete Cable. 30° C. C.
Inner Length
r Insulatio PVC r of Cable Strip PVC r of Wire PVC r of
Sheath .
n Outer Cable. Outer Cable. Outer Cable.
Sheath Sheath Sheath
Sq.mm mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
.
70 5.5 0.6 3.0 58.0 3550 0.8 2.2 58.0 4300 2.5 2.36 61.5 5900 160 140 190 500
95 5.5 0.6 3.2 62.0 4100 0.8 2.36 62.0 4900 3.15 2.52 66.5 7250 190 165 230 500
120 5.5 0.7 3.2 65.0 4650 0.8 2.36 65.0 5500 3.15 2.52 70.0 8000 220 190 260 500
150 5.5 0.7 3.4 68.5 5200 0.8 2.52 68.5 6100 3.15 2.68 73.0 8650 245 210 295 500
185 5.5 0.7 3.4 71.5 5900 0.8 2.68 71.5 6950 3.15 2.84 77.0 9650 275 240 335 500
240 5.5 0.7 3.6 77.0 6850 0.8 2.84 77.0 7900 3.15 3.0 82.0 10850 315 275 395 250
300 5.5 0.7 3.8 81.5 7850 0.8 3.0 81.5 8950 4.0 3.0 88.0 13250 355 310 450 250
400 5.5 0.7 4.0 88.0 9400 0.8 3.0 88.0 10500 4.0 3.0 94.5 15200 400 350 520 250

TABLE 26 - 11 / 11 KV (UE) HT XLPE THREE CORE COPPER CONDUCTOR CABLES

“POLYCAB” THREE CORE COPPER CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES CONFORMING TO IS:
7098 PART-2/1985:
UNARMOURED CABLE FORMED WIRE / STRIP ARMOURED ROUND WIRE ARMOURED CABLE CURRENT CARRYING
Minimu CABLE CAPACITY
Nomina
Nomina
m *Norm
l l Nomon Approx Appro Nominal Minimu Approx Approx Nominal Minimu Approx Approx In In In Air
Thicknes al
Size
Thicknes al . x Dimensio m . . Weight Dimensio m . . Weight Ground Duct at
s of Deliver
of s of Thicknes Overall Weigh n of GI Thicknes Overall of n of GI Thicknes Overall of at at 30° 40°
PVC y
Conducto XLPE s of Diamete t of Flat s of Diamete Cable. Round s of Diamete Cable. 30° C. C. C.
Inner Length
r Insulatio PVC r of Cable Strip PVC r of Wire PVC r of
Sheath .
n Outer Cable. Outer Cable. Outer Cable.
Sheath Sheath Sheath
Sq.mm. mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
70 5.5 0.6 3.0 58.0 4900 0.8 2.2 58.0 5600 2.5 2.36 61.5 7150 210 180 240 500
95 5.5 0.6 3.2 62.0 5900 0.8 2.36 62.0 6700 3.15 2.52 66.5 9000 250 215 295 500
120 5.5 0.7 3.2 65.0 6900 0.8 2.36 65.0 7750 3.15 2.52 70.0 10250 280 240 335 500
150 5.5 0.7 3.4 68.5 8000 0.8 2.52 68.5 8900 3.15 2.68 73.0 11450 310 270 380 500
185 5.5 0.7 3.4 71.5 9300 0.8 2.68 71.5 10300 3.15 2.84 77.0 13100 350 305 430 250
240 5.5 0.7 3.6 77.0 11300 0.8 2.84 77.0 12350 3.15 3.0 82.0 15350 400 350 500 250
300 5.5 0.7 3.8 81.5 13400 0.8 3.0 81.5 14500 4.0 3.0 88.0 18850 445 390 570 250
400 5.5 0.7 4.0 88.0 16850 0.8 3.0 88.0 17950 4.0 3.0 94.5 22650 500 440 650 250
The above data is approximate and subject to manufacturing tolerance.
* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.
26
 WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF AN ISO 9001:2000
COMPANY

CABLES TABLE 27 - 12.7/22 KV (E) HT XLPE THREE CORE ALUMINIUM CONDUCTOR CABLES
“POLYCAB”THREE CORE ALUMINIUM CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES CONFORMING
TO IS: 7098 PART-2/1985:
UNARMOURED CABLE FORMED WIRE / STRIP ARMOURED ROUND WIRE ARMOURED CABLE CURRENT CARRYING
Minimu CABLE CAPACITY
Nomina
Nomina
m *Norm
l l Nomon Approx Appro Nominal Minimu Approx Approx Nominal Minimu Approx Approx In In Duct In Air
Thicknes al
Size
Thicknes al . x Dimensio m . . Weight Dimensio m . . Weight Ground at 30° at
s of Deliver
of s of Thicknes Overall Weigh n of GI Thicknes Overall of n of GI Thicknes Overall of at C. 40°
PVC y
ConductoXLPE s of Diamete t of Flat s of Diamete Cable. Round s of Diamete Cable. 30° C. C.
Inner Length
r Insulatio PVC r of Cable Strip PVC r of Wire PVC r of
Sheath .
n Outer Cable. Outer Cable. Outer Cable.
Sheath Sheath Sheath
Sq.mm mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
.
95 6.0 0.7 3.2 64.0 4450 0.8 2.36 64.0 5300 3.15 2.52 69.0 7750 190 170 230 500
120 6.0 0.7 3.4 67.5 5050 0.8 2.52 67.5 5900 3.15 2.68 72.0 8500 215 190 265 500
150 6.0 0.7 3.4 70.5 5550 0.8 2.68 70.5 6500 3.15 2.68 75.5 9200 240 215 300 250
185 6.0 0.7 3.6 74.0 6300 0.8 2.68 74.0 7250 3.15 2.84 79.0 10150 270 240 340 250
240 6.0 0.7 3.8 79.5 7300 0.8 2.84 79.0 8300 4.0 3.0 85.5 12600 310 275 400 250
300 6.0 0.7 4.0 84.0 8300 0.8 3.0 83.5 9350 4.0 3.0 90.0 13850 350 310 455 250
400 6.0 0.7 4.0 90.5 9850 0.8 3.0 90.5 10950 4.0 3.0 96.5 15800 395 355 530 250

TABLE 28 - 12.7 / 22 KV (E) HT XLPE THREE CORE COPPER CONDUCTOR CABLES

“POLYCAB” THREE CORE COPPER CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES CONFORMING TO IS:
7098 PART-2/1985:
UNARMOURED CABLE FORMED WIRE / STRIP ARMOURED ROUND WIRE ARMOURED CABLE CURRENT CARRYING
Minimu CABLE CAPACITY
Nomina
Nomina
m *Norm
l l Nomon Approx Appro Nominal Minimu Approx Approx Nominal Minimu Approx Approx In In Duct In Air
Thicknes al
Size
Thicknes al . x Dimensio m . . Weight Dimensio m . . Weight Ground at 30° at
s of Deliver
of s of Thicknes Overall Weigh n of GI Thicknes Overall of n of GI Thicknes Overall of at C. 40°
PVC y
ConductoXLPE s of Diamete t of Flat s of Diamete Cable. Round s of Diamete Cable. 30° C. C.
Inner Length
r Insulatio PVC r of Cable Strip PVC r of Wire PVC r of
Sheath .
n Outer Cable. Outer Cable. Outer Cable.
Sheath Sheath Sheath
Sq.mm mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
.
95 6.0 0.7 3.2 64.0 6200 0.8 2.36 64.0 7050 3.15 2.52 69.0 9500 245 215 300 500
120 6.0 0.7 3.4 67.5 7300 0.8 2.52 67.5 8150 3.15 2.68 72.0 10750 275 245 340 500
150 6.0 0.7 3.4 70.5 8300 0.8 2.68 70.5 9300 3.15 2.68 75.5 11950 305 275 385 250
185 6.0 0.7 3.6 74.0 9750 0.8 2.68 74.0 10700 3.15 2.84 79.0 13600 345 305 435 250
240 6.0 0.7 3.8 79.5 11750 0.8 2.84 79.0 12750 4.0 3.0 85.5 17050 395 350 510 250
300 6.0 0.7 4.0 84.0 13900 0.8 3.0 83.5 14950 4.0 3.0 90.0 19400 440 390 580 250
400 6.0 0.7 4.0 90.5 17250 0.8 3.0 90.5 18400 4.0 3.0 96.5 23250 495 440 660 200

The above data is approximate and subject to manufacturing tolerance.

* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.
26
WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF AN ISO 9001:2000
COMPANY

CABLES TABLE 29 - 19 / 33 KV (E) HT XLPE THREE CORE ALUMINIUM CONDUCTOR CABLES

“POLYCAB”THREE CORE ALUMINIUM CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES CONFORMING
TO IS: 7098 PART-2/1985:
UNARMOURED CABLE FORMED WIRE / STRIP ARMOURED ROUND WIRE ARMOURED CABLE CURRENT CARRYING
Minimu CABLE CAPACITY
Nomina
Nomina
m *Norm
l l Nomon Approx Appro Nominal Minimu Approx Approx Nominal Minimu Approx Approx In In Duct In Air
Thickness al
Size
Thicknes al . x Dimensio m . . Weight Dimensio m . . Weight Ground at 30° at
of PVC Deliver
of s of Thicknes Overall Weigh n of GI Thicknes Overall of n of GI Thicknes Overall of at C. 40°
Inner y
ConductoXLPE s of Diamete t of Flat s of Diamete Cable. Round s of Diamete Cable. 30° C. C.
Sheath Length
r Insulatio PVC r of Cable Strip PVC r of Wire PVC r of
.
n Outer Cable. Outer Cable. Outer Cable.
Sheath Sheath Sheath
Sq.mm mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
.
95 8.8 0.7 3.6 77.0 6050 0.8 2.84 77.0 7100 3.15 3.0 82.0 10050 190 170 230 500
120 8.8 0.7 3.8 80.5 6750 0.8 2.84 80.5 7750 4.0 3.0 86.5 12100 215 190 265 500
150 8.8 0.7 4.0 83.5 7400 0.8 3.0 83.5 8400 4.0 3.0 90.0 12800 240 215 300 250
185 8.8 0.7 4.0 87.0 8150 0.8 3.0 87.0 9250 4.0 3.0 93.0 13900 270 240 340 250
240 8.8 0.7 4.0 91.5 9150 0.8 3.0 91.5 10300 4.0 3.0 98.0 15150 310 275 400 250
300 8.8 0.7 4.0 96.0 10200 0.8 3.0 96.0 11350 4.0 3.0 102.0 16450 350 310 455 250
400 8.8 0.7 4.0 102.5 11800 0.8 3.0 102.5 13100 4.0 3.0 109.0 18550 395 355 530 250

TABLE 30 - 19 / 33 KV (E) HT XLPE THREE CORE COPPER CONDUCTOR CABLES

“POLYCAB” THREE CORE COPPER CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES CONFORMING TO IS:
7098 PART-2/1985:
UNARMOURED CABLE FORMED WIRE / STRIP ARMOURED ROUND WIRE ARMOURED CABLE CURRENT CARRYING
Minimu CABLE CAPACITY
Nomina
Nomina
m *Norm
l l Nomon Approx Appro Nominal Minimu Approx Approx Nominal Minimu Approx Approx In In Duct In Air
Thicknes al
Size
Thicknes al . x Dimensio m . . Weight Dimensio m . . Weight Ground at 30° at
s of Deliver
of s of Thicknes Overall Weigh n of GI Thicknes Overall of n of GI Thicknes Overall of at C. 40°
PVC y
ConductoXLPE s of Diamete t of Flat s of Diamete Cable. Round s of Diamete Cable. 30° C. C.
Inner Length
r Insulatio PVC r of Cable Strip PVC r of Wire PVC r of
Sheath .
n Outer Cable. Outer Cable. Outer Cable.
Sheath Sheath Sheath
Sq.mm mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
.
95 8.8 0.7 3.6 77.0 7850 0.8 2.84 77.0 8900 3.15 3.0 82.0 11800 245 215 300 250
120 8.8 0.7 3.8 80.5 9000 0.8 2.84 80.5 10000 4.0 3.0 86.5 14300 275 245 340 250
150 8.8 0.7 4.0 83.5 10150 0.8 3.0 83.5 11200 4.0 3.0 90.0 15600 305 275 385 250
185 8.8 0.7 4.0 87.0 11600 0.8 3.0 87.0 12700 4.0 3.0 93.0 17300 345 305 435 250
240 8.8 0.7 4.0 91.5 13600 0.8 3.0 91.5 14750 4.0 3.0 98.0 19600 395 350 510 250
300 8.8 0.7 4.0 96.0 15750 0.8 3.0 96.5 16950 4.0 3.0 102.0 22000 440 390 580 200
400 8.8 0.7 4.0 102.5 19250 0.8 3.0 102.5 20550 4.0 3.0 109.0 26000 495 440 660 200

The above data is approximate and subject to manufacturing tolerance.

* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.
27
 WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF AN ISO 9001:2000
COMPANY

CABLES TABLE 31 - 33 / 33 KV (UE) HT XLPE THREE CORE ALUMINIUM CONDUCTOR CABLES

“POLYCAB”THREE CORE ALUMINIUM CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES CONFORMING
TO IS: 7098 PART-2/1985:
UNARMOURED CABLE FORMED WIRE / STRIP ARMOURED ROUND WIRE ARMOURED CABLE CURRENT CARRYING
Minimu CABLE CAPACITY
Nomina
Nomina
m *Norm
l l Nomon Approx Appro Nominal Minimu Approx Approx Nominal Minimu Approx Approx In In Duct In Air
Thickness al
Size
Thicknes al . x Dimensio m . . Weight Dimensio m . . Weight Ground at 30° at
of PVC Deliver
of s of Thicknes Overall Weigh n of GI Thicknes Overall of n of GI Thicknes Overall of at C. 40°
Inner y
ConductoXLPE s of Diamete t of Flat s of Diamete Cable. Round s of Diamete Cable. 30° C. C.
Sheath Length
r Insulatio PVC r of Cable Strip PVC r of Wire PVC r of
.
n Outer Cable. Outer Cable. Outer Cable.
Sheath Sheath Sheath
Sq.mm mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
.
120 9.5 0.7 4.0 84.0 7600 0.8 3.0 83.5 8650 4.0 3.0 90.0 12700 215 190 265 500
150 9.5 0.7 4.0 87.0 8150 0.8 3.0 86.5 9250 4.0 3.0 93.0 13450 240 215 300 250
185 9.5 0.7 4.0 90.0 8950 0.8 3.0 89.5 10100 4.0 3.0 96.0 14550 270 240 340 250
240 9.5 0.7 4.0 94.5 10000 0.8 3.0 94.5 11200 4.0 3.0 101.0 15850 310 275 400 250
300 9.5 0.7 4.0 99.0 11050 0.8 3.0 98.5 12300 4.0 3.0 105.0 17300 350 310 455 250
400 9.5 0.7 4.0 105.5 12750 0.8 3.0 105.0 14100 4.0 3.0 112.0 19350 395 355 530 250

TABLE 31 - 33 / 33 KV (UE) HT XLPE THREE CORE COPPER CONDUCTOR CABLES

“POLYCAB”THREE CORE COPPER CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES CONFORMING TO IS:
7098 PART-2/1985:
UNARMOURED CABLE FORMED WIRE / STRIP ARMOURED ROUND WIRE ARMOURED CABLE CURRENT CARRYING
Minimu CABLE CAPACITY
Nomina Nomina
m *Norm
l l Nomon Approx Appro Nominal Minimu Approx Approx Nominal Minimu Approx Approx In In Duct In Air
Thicknes al
Size Thicknes al . x Dimensio m . . Weight Dimensio m . . Weight Ground at 30° at
s of Deliver
of s of Thicknes Overall Weigh n of GI Thicknes Overall of n of GI Thicknes Overall of at C. 40°
PVC y
Conducto XLPE s of Diamete t of Flat s of Diamete Cable. Round s of Diamete Cable. 30° C. C.
Inner Length
r Insulatio PVC r of Cable Strip PVC r of Wire PVC r of
Sheath .
n Outer Cable. Outer Cable. Outer Cable.
Sheath Sheath Sheath
Sq.mm mm mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps. Mtrs.
.
120 9.5 0.7 4.0 84.0 9800 0.8 3.0 83.5 10850 4.0 3.0 90.0 14950 275 245 340 250
150 9.5 0.7 4.0 87.0 10950 0.8 3.0 86.5 12000 4.0 3.0 93.0 16250 305 275 385 250
185 9.5 0.7 4.0 90.0 12400 0.8 3.0 89.5 13550 4.0 3.0 96.0 18000 345 305 435 250
240 9.5 0.7 4.0 94.5 14450 0.8 3.0 94.5 15650 4.0 3.0 101.0 20300 395 350 510 250
300 9.5 0.7 4.0 99.0 16650 0.8 3.0 98.5 17900 4.0 3.0 105.0 22900 440 390 580 200
400 9.5 0.7 4.0 105.5 20150 0.8 3.0 105.0 21550 4.0 3.0 112.0 26750 495 440 660 200

The above data is approximate and subject to manufacturing tolerance.

* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.
28
HANDLING, STORAGE AND LAYING OF POLYCAB CABLES AN ISO 9001:2000 COMPANY

A. CABLE INSPECTION B. CABLE HANDLING & STORAGE

Inspect every cable reel for damage Damage to cables can occur due to the
before accepting the shipment. Be incorrect handling to which the drums
particularly alert for cable damage if: and cables may be subjected; causing
1. A reel is lying flat on its side breakdown of the drum flanges and in
2. Several reels are stacked exceptional cases, movement of the
drum barrel takes place.Once this
3. Other freight is stacked on a reel
breakdown of the drum occurs, the
4. Nails have been driven into reel cable is immediately exposed to
flanges to secure shipping blocks damage. Cables damaged during
5. A reel flange is damaged handling & storage can cause service
6. A cable covering is removed, failures when the subject cable is put
stained or damaged to use.
7. A cable end seal is removed or damaged. Thus the following is a list of Do’s and
A reel has been dropped (hidden Don’ts that should be followed while
damage likely) handling and storing the cables before
it is put to use.

Do’s Don’ts
When off loading reels from a Never drop reels. If reels must be
truck, lower reels carefully using a rolled, roll in opposite direction of
hydraulic gate, hoist or forklift truck the cable wraps to keep cable from
loosening on the reel.

If a fork lift is used, approach the Do not allow the lift forks to
reel from the flange side. Position the contact the cable. Care must be
forks such that the reel is lifted by taken by the fork lift operator not
both reel flanges. Also to make sudden turns or stops.
Consideration should be given to,
Traffic patterns during off-loading
& damage during the time in
storage
Cable reels should be stored on Multiple reels stacked on top of each
hard surfaces resting on the other (“Pancake” storage) is not
flanges edge (flanges vertical). recommended for cable drums.
Align reels flange to flange and, if The weight of the stack can total
possible, arrange so that first in is thousands of kgs. creating an
first out. enormous load on the bottom reel.
Also, damage to the reel and/or
cable will likely occur when the reel
is flipped for transit. A
concentration of stress on the reel
flange may cause it to break and
subsequently damage the cable.

29
 When using a hoist, install a This may lead to the bending of the
mandrel through the reel arbor reel flanges and mashing the cable
holes and attach a sling. Use a

WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF

spreader bar approximately 6
inches longer than the overall reel
width placed between the sling AN ISO 9001:2000
COMPANY

CABLES
ends just above the reel flanges.

TABLE 31 - 33 / 33 KV (UE) HT XLPE THREE CORE ALUMINIUM CONDUCTOR CABLES

“POLYCAB”THREE CORE ALUMINIUM CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES CONFORMING
TO IS: 7098 PART-2/1985:

The above data is approximate and subject to manufacturing tolerance.

* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.
30
 HANDLING, STORAGE AND LAYING OF POLYCAB CABLES AN ISO 9001:2000 COMPANY

C. PRE- INSTALLATION 4. Shaft supported both ends with

To ensure safety during cable suitable jacks / stands.
installation, following shall be 5. Under no circumstances the cable
checked prior to installation. winding shall be lifted off a coil or
1. The cable selected is proper for drum lying flat at the flanges. This
designed application. would cause serious twist and
2. The cable has not been damaged damages.
in transit or storage. 6. Suitable protection shall be
Review all applicable state and national provided to the cables against
codes to verify that the cable chosen mechanical damages, it includes
is appropriate for the job. Also covers, pipes etc.
consult your local electricity E. RECOMMENDED MINIMUM BENDING
authority. Next, you must identify any RADIUS FOR HEAVY DUTY CABLES.
existing cable damage and prevent
Single Core : 20 x D
any further damaged from occurring.
This is done through proper cable Multicore : 15 x D
inspection, handling and storage. Where D= Diameter of cable in mm
D. INSTALLATION & LAYING F. RECOMMENDED SAFE PULLING FORCE
WITH STOCKINGS:
Mechanical stresses during
installation are a) For Unarmoured Cable: P =
generallymoreseverethanthoseencou 5 D2 Where P= Pulling
ntered while in service. Thus care should Force
be taken as regards to the following
while installation and laying of cables. b) For Armoured Cable : P = 9
1. Polycab recommendthe laying D2 Where D= Diameter of
and installation of cables cable in mm
as per IS: 1255/84.
G. RECOMMENDED SAFE PULLING FORCE
2. Care shall be taken during laying to WHEN PULLED WITH PULLING EYE :
avoid sharp bending, and twisting.
a) For Aluminium Conductors : 30 N/mm2
3. Cable shall be un wound from the
drum by lifting the drum on the b) For Copper Conductor : 50 N/mm2
center

30
 DO NOT ATTEMPT “COILING” OF CABLE ON THE GROUND

ON THE GROUND CABLE CAN BE FLAKED IN A FIGURE OF EIGHT FORMATION

Note: R Minimum Permissible bending radius of cable.

31
 IMPORTANT FORMULAE AN ISO 9001:2000 COMPANY

IMPORTANT FORMULAE * TO CALCULATE VARIOUS ELECTRICAL PARAMETERS OF CABLES

1) Inductance : 7) Dielectric loss in watts per km/phase:

L = K + 0.2 loge 2S (mH/km)
2 f x C Uo2 tan 10-6 (watt / km per phase)
d
where K = Constant for different stranded where C = Capacitance
conductors S = Axial Spacing Uo = Power frequency voltage between
between Cables & conductor & earth
Conductors in Tan = Dielectric power factor
mm. d = = 0.0003 for XLPE
Conductor Diameter
No. of wires in Conductor K 8) Voltage Induced in Sheath :
7 0.064
2 ES = IXm
19 0.055
4 where I = conductor current
37 0.052
8 (A) Xm = 2 fM x 10–3
61 0.051 ( / km)
4 2S
Above 61 0.050 M = 0.2 loge (mH/km)
0 dm
S = Distance between Cable Centres, dm
2) Reactance : = Mean Diameter of Sheath

X = 2 f x L x 10-3  / km
9) Short Circuit Rating:
where f = frequency
L = Inductance K2 S2 1
+
0
3) Impedance :
Z = (R2 + X2) ½  / km
where R = A.C Resistance at operating temperature I2 loge
 / km = T
X = Reactance
6) Capacitance:
4) Charging Current : Er
C= ( µf / km) 18 loge (D/d)
A = Uo x 2 x f x C x 10-6  / km
where Er = Relative Permitivity for XLPE : 2.3 D = Dia
over Insulation in mm
5) Voltage Drop :
d = Dia over conductor in mm
For 3 Core Cables : 3 x Z
V/A/Mtr For 1 Core Cables : 2
xZ
where Z = Impedance

32
where I = Short circuit (R.M.S over duration) in
Amps.
T = Duration of short circuit in second
K = Constant – 226 for
Copper, 148 for
Aluminium, 78 for
Steel
S = Area of Conductor in mm2
1 = Final Temperature of
Conductor or Armour
0 = Initial Temperature of
Conductor or Armour
 = Reciprocal of
the
temperature
coefficient of
resistance of
the conductor
per° C at 0° C
(228 for
Aluminium,
202 for Steel,
& 234.5 for
Copper)

* source
BICC
handbook

33
 DIFFERENCE BETWEEN EARTHEDIUNEARTHED SYSTEM AN ISO 9001:2000 COMPANY

EARTHED SYSTEM: UNEARTHED SYSTEM:

In the initial years,the generators and Today generators of 500 MVA capacity
transformers were having capacities of are in commercial use. More over several
few MVA and hence fault current was mega power stations are connected to
also less. The star point or neutral point grid. Due to this, the fault level has
was solidly grounded and this is called increased tremendously. In case of an
earthed system. earth fault, a heavy current flows in to the
fault and this may damage the costly
R generators and power transformers.

N To reduce the fault current, the star point

Y
is connected to the earth through a
resistance or a reactance as under:
B

R
In this system if an earth fault occurs on any of the
N EARTH
phases, the voltages of other two healthy phases Y

with respect to the earth remain the same. VR

B

In this case if an earth fault occurs on R

phase, the voltage of the faulty phase with
respect to the earth
(R) appears across the current limiting
resistance or reactance in the earth
circuit of the star point and as a result
the voltage of the star point which was at
earth potential under normal conditions
rises to VR. Due to this the voltages of
other two healthy phases (B and Y) with
respect to the earth rises by 1.7 times
(Vector sum of VR and VB). If the insulation
of these phases are not designed for
these increased voltages they may
develop earth fault. This is called

32
Unearthed System.

33
 Production Facilities at Daman Factory

34
 Wiring the World

WIRES & CABLES

Polycab Wires PVt. ltd.

(an ISO 9001:2000 Company)

Regd. & Head office :

Hico House, 1st floor, Pandit Satawalekar Marg,
Mahim (W), Mumbai 400 016.
Tel. : 91-22-2432 7070 - 4, 2436 2199, 2432 9118
Fax : 91-22-2432 7075
E-mail :
polycab@vsnl.com Website
: www.polycab.com
POLYCAB WIRES PVT LTD
TECHNICAL DETAILS

HT XLPE CABLES
UPTO 132Kv
WIRES & CABLES

CONTENTS

(1) COMPANY INTRODUCTION

(2) INTRODUCTION TO POLYCAB XLPE CABLES UPTO 132 KV
(3) PROCESS FLOW DIAGRAM
(4) MATERIAL HANDLING & ENVIRONMENT CONTROL
(5) QUALITY PLANNING AND PROCESS OF PRODUCTION
(6) QUALITY ASSURANCE.
ROUTINE / TYPE TESTING &
STANDARDS

(7) TECHNICAL DATA - CABLE CONSTRUCTION

(8) ELECTRICAL DATA
(9) CABLE TERMINATIONS
(10) CABLE HANDLING – PRE INSTALLATION
(11) CURRENT RATING & RATING FACTORS
(12) SHEATH BONDING SYSTEMS

1
WIRES & CABLES

INTRODUCTION
Polycab - Experience & Trust: 66 KV & 132 KV XLPE CABLES

Polycab is the fastest growing cable Cables for transmission of Power at 66 KV

manufacturer in India. “Polycab” has and 132 KV are used in Power Plants, and
earned trust and confidence of distribution systems of utilities and
Industries consuming bulk power. Where
customers over 3 decades of
overhead lines are not suitable due to
performance. densely built areas and buildings in cities, the
use of these cables have become inevitable.
Today being leader in India and South
East Asia, Polycab manufactures The cables are designed to be used
Electrical Power and communication underground directly, buried in ducts,
cables. Strategic control over basic trenches or in tunnels.
raw materials and wide range of
Polycab cables are successfully type tested as
cables from 1.1 kV to 132 kV has given
per IEC 60840 and IS:7098 Part 3 for all
an edge and ensured phenomenal critical electrical, Mechanical, thermal and
growth. installation parameters, ensuring the quality
and reliability.
Million lengths of cables
manufactured by Polycab in different MANUFACTURING PROCESS
voltage grades are in operation for
years. Polycab 132 & 66 KV cables are manufactured on
the most modern and state of the art Dry-curing
Inspired by customer support, Polycab has CCV (continuous Catenary Vulcanization) XLPE
enhanced the manufacturing ability with 66 kV Insulation Line. True Triple Extrusion, Dust free
and 132 kV production facilities. environment and On-Line Thickness measurement
and control are the highlights of manufacturing
process which ensures consistency in quality
standards.

2
WIRES & CABLES

XLPE CABLES (2) XLPE cables – properly designed,

manufactured and installed – are
XLPE insulated cables are increasingly reliable and have a long service life
replacing conventional oil-filled paper expectancy.
insulated cables for higher service voltage
up to 220 kV. Also EHV cable up to 500 kV (3) XLPE cables are lighter and easier to
are being manufactured with XLPE handle, thus reducing the installation
insulation and slowly replacing oil filled costs.
cables.
(4) Jointing and terminations are easier with
As experienced over twenty years, the
XLPE cables.
XLPE EHV cable links showed no
fundamental failures, such as, internal (5) XLPE cables do not contain oil and are
breakdowns or premature ageing. therefore pro-environmental.
Actually these cables have surpassed the
performance of oil filled paper insulated (6) XLPE cables require lesser maintenance.
cables in many areas for their long term
reliability under all kinds of practical In fact certain countries have stopped using
service conditions. oil filled cable due to pollution aspects.
The advantages for the substitution of Out of various process being used today,
XLPE cables as compared to oil filled Polycab manufactures EHV Cables with a dry
cables are as: cure/dry cool technology with Scholz,
Germany and Royal U.S.A. manufacturing
(1) XLPE cables have extremely low lines.
dielectric losses and are therefore
economical in use. The important feature of this technology are
discussed in the following pages in detail.

SCHEMATIC DIAGRAM OF TYPICAL POLYCAB EHV- CABLES FROM 66 TO 132 KV

ComDucTOe Cu/Aı.
ExTeuDED SEпıcomDucTImG SceEEm
SueEe CıE‫ם‬m XLPE
ExTeuDED SEпıcomDucTImG SceEEm W
‫ם‬TEe SwEıı‫ם‬bıE SEпıcomDucTImG T‫ם‬
eE
LE‫ם‬D AııoY E S+E‫ם‬T+ oe PoıY −Aı T‫ם‬
eE
SEICOmDucTImG BEDDımG T
‫ם‬eE CoeeEe oe Aıuпımıuп
SceEEm

OuTEe S+E ‫ם‬T+ PVC/HDPE

3
WIRES & CABLES

PROCESS FLOW DIAGRAM OF XLPE CABLES FOR 66 & 132 KV

CONDUCTOR

Semi
conductingTa
pe as
required.
Continuous Tripple
Extrusion Inner
Semicon
XLPE Insulation (Super
Clean) Outer

CCV from
Dry Cure
Dry Cool/Water
Cool

Semi conducting Water

Swellable Tape

Extruded Lead Alloy “E”

Sheath / Poly-AL

Semi conducting
Tape Bedding

Screen – Copper Wires /

Aluminium Wires

HDPE / PVC Sheath -

Graphite Coating

Testing

Packing

Despatch / Shipping

4
WIRES & CABLES

Therefore the material transportation

MATERIAL HANDLING & system includes clean air washing of all
ENVIRONMENT CONTROL materials delivery containers, feeding of
insulating and semiconducting
MANUFACTURING PROCESS HIGHLIGHTS compounds to the clean rooms having
buffers, and finally supplying to hopper
Super Clean grades of insulating material dryers in closed stainless steel pipes,
consisting basically of high purity ensuring the followings:
polyethylene with a cross-linkable structure
especially developed for the manufacturing  Minimum personal contact with
of high voltage cables are used. The material.
compound meets the stringent requirement
of cleanliness. The suppliers are selected  Prevention of contamination
from the leading manufacturers of XLPE entering into the insulation or semi
material in the world. conducting material.

Also the semi-conductive material is  Removes materials fins if any

selected based on its compatibility with associated with the material
insulation and having uniform surface conveying.
smoothness and excellent extrusion
properties. The entire insulation process is
performed in clean room condition and
A contamination free insulation is essential positive pressure to maintain conducive
when demanding a long lifetime under high environment.
electrical stress.

CLEAN ROOM

Semicon Extruders
5

Main XLPE Insulation extruders

XLPE CONTAINER TRANSPORTATION TO MANUFACTURING LINES

5
WIRES & CABLES
QUALITY PLANNING AND PROCESS OF PRODUCTION

In extra high voltage application, there are hopper of extruders. The

three polymeric layers over the conductor.
The first layer comprises of a conductor
screen, (semi conducting compound and
semi conducting tape – optional), the XLPE
insulation (Super Smooth Clean Grade of
XLPE Compound) and an insulation screen.
The protective layers consisting of the
bedding, a copper wire screen or tape
screen, metallic (lead sheath) or non-metallic
Poly Al. Sheath outer PVC/HDPE sheath.

PROCESS
(a) Conductor: The conductor is made form
high purity Copper or Aluminium rods. These
rods are drawn to specific diameter wire with
excellent smoothness, cylindercity and
online annealing. These wires are then
compacted to required size conductor with
very good compactness & smoothness. The
conductors are measured online for
conductor resistance by Asea Cartelloid,
(Switzerland) online instrument conductor
meets Standard IEC-60228, IS:8130.

(b) XLPE Insulation (Continuous Tripple

Extrusion & Continuous Catenary
Vulcanization): The insulation process is the
most critical phase of the manufacturing
chain, as the insulation layer of a high
voltage or extra high voltage cable is under
high electrical stress and it has to be free
from defects.

During extrusion, the compound are handled

with due care reducing possibility of
contamination and fed directly to the

6
temperature profile of all three extruders
& the head is controlled by computers
with in an accuracy of ± 1°C. All
requirements are preprogrammed. The
triple crosshead and all extruders are
from Royal, USA, ensuring uniform layers
of semi-conducting and insulation.
Insulated conductor dimension such as
diameter, thickness of each layer and
eccentricity is controlled by online x-ray
monitoring equipment from Zumbach,
Germany, to ensure the consistency.

Continous Catenary Vulcanization : The

insulated conductor then enters a
heated vucanization zone located within
a tube of 200 mm diameter and 140
mtrs. long, in “Catenany” form. The
heating is done using inert & dry
pressurized (10-12 bar) Nitrogen gas to
minimize voids and moisture content.

5
WIRES & CABLES

Also the hot dry nitrogen sweeps away all controls the output and dimensions of the
volatiles such as peroxides, acetophenone, lead alloy, to required thickness.
methane, methylstyrene, ethane and water
vapours. The M/C is equipped with auto
centering device and also fixed with X’Ray
machinery equipped from Zumbatch,
Germany for Tripple Extrusion. The dry cool
zone of this Catenary tube of CCV line
provides stress relaxation in the core
particularly the innermost layer of the
insulation, in addition to the cooling of the
insulated conductor.

The complete CCV line is automated with

programming system and ensures
achievement of required parameters.

(c) Taping: Semi-conducting Water Blocking

or water swellable tape of superior quality
are applied on the insulated conductor. This
being done on double helical tape dispenser
machines with synchronized payoffs and
take ups.

(d) Extruded Lead Alloy ‘E’ Sheathing:

Introduction: Basic purpose of lead sheathing

is to protect the core and prevent moisture
reaching the insulation during service.

The inherent inertness and excellent

corrosion resistance of lead and moisture
repellent nature made it an obvious choice
for underground cables. Continuous Lead
extruders are used for this process.

Process: Lead Ingot of 99.98% min. purity is

used and melted in the melting pot of 10
tons capacity at approx. 370°C also added
master batch to bring right metallurgy to
make lead alloy ‘E’, which yields to good
extrusion, softwares, smoothness and
pliability in lead sheathing.

After melting the lead is transported by a

gravity feed pipe (in special omega shape
to handle heat stresses) to the vertical
screw housing at the bottom and the
rotating screw transports the lead alloy up
to the die block, with water cooling system
to control the plasticity of the lead. From
cross head die block lead alloy is forced to
form the tube. The computerized system
7
1. Taping : Semi Conducting Cotton Tape
are helically wound on the core as
bedding.

2. Copper Screening & Taping : The

metallic part of the screening consists
of copper wires /copper tape (s)
helically applied over the lead alloy
sheath bedding. Screening is normally
selected – based on the fault current
requirement.

3. Sheathing with graphite coating:

Sheathing is either of PVC or of Black
Polyethylene.
QUALITY ASSURANCE AND TESTING
4. Testing : All cable drums are tested for
High voltage test, partial discharge and
Conductor Resistance, as per IS:7098
Part 3 or IEC 60840. Online inspection
is carried by stagewise physical
inspection and measurement of
thickness, diameter, voids and
eccentricity and hot set test. The
verification of cable is done with
detailed cable engineering Data
sheets.
Quality Assurance Testing: Polycab EHV
Cables are tested to ensure high reliability
in performance. Continuous process
monitoring and post manufacturing tests
to ensure the compliance to Indian and
International Standards.

Polycab is self sufficient to carry out all

Routine, Type & Special Tests in the
laboratory. It has world class Testing
facilities for Routine & Type Tests.

IMPULSE GENERATOR

8
WIRES & CABLES

(A) Routine Tests:

 Partial Discharge Test

 High Voltage Test
 Conductor Resistance Test.

Routine Tests are performed on each

manufactured length of cable in Routine
Test Laboratory.

Type Tests: Type Test is performed on a

representative sample.

i) Electrical: All electrical type tests as per IEC

60840 or IS:7098 Part 3 are carried out on the
cable samples.

ii) Non-Electrical: All non- electrical type

tests as per IEC 60840 or IS:7098 Part 3 are
carried out on the cable samples.

COMPUTERISED PARTIAL DISCHARGE DETECTOR

BASIC DESIGN OF 66 & 132 KV CABLES

Polycab 66 & 132 KV XLPE Cables are

designed to meet requirement of
customer and those set in national and
international standards mainly Indian
Standard IS-7098 Part 3 and IEC 60840.

Polycab has established system of

Quality Management which complies
ROUTINE TEST ENCLOSURE ISO 9001 requirements and ensures
customer needs and expectations.

9
WIRES & CABLES

APPLICABLE STANDARDS FOR XLPE CABLES 66 KV & 132 KV

The cable systems described in this publication generally conform, where appropriate, to the
following standards:
1. IS Standards 7098 Part 3 Cross-Linked Polyethylene Insulated Thermoplastic Sheathed Cables -
Specification. Part - 3 for working voltages from 66 Kv up to and including 220
kV.
2. IEC Publication 60228 Conductors of Insulated Cables.
3. IEC Publication 60502 Extruded Solid Dielectric Insulated Power Cables for Rated Voltages from 1 kV to
30 kV.
4. IEC 60840 Power cables with extruded insulation and their accessories for rated voltages
above 30 kV (Um = 36 kV) up to 150 kV (Um = 170 kV) - Test methods and
requirements
5. IEC – 60287 Electric Cables calculation of current rating.
6. IEC- 60332 Tests on Electric cables under fire conditions.

Test Requirement of 66 & 132 kV Cables as per IEC 60840 and IS:7098 Part 3
Type Designation
Non-
No. Description of the Test Routine Special Elect. Elect
.
1 Partial Discharge Test X X
2 Voltage Test X X
3 Electrical test on non-metallic sheath (if required) X
4 Conductor examination X X
5 Measurement of electrical resistance of conductor X X
6 Measurement of thickness of insulation and non-metallic sheaths X X
7 Measurement of thickness of metallic sheaths X X
8 Measurement of diameters (if required) X
9 Hot set test for XLPE Insulation X X
10 Measurement of capacitance X
11 Check on insulation thickness of cable for electrical type tests X
12 Bending test followed by partial discharge test
13 Tangent Delta Measurement
14 Heating Cycle voltage test, followed by partial discharge test
15 Impulse withstand test followed by a power frequency voltage test
16 Resistivity of semi-conducting layers.
17 Determining the mechanical properties of insulation before and after X
ageing.
Determining the mechanical properties of non-metallic sheath
18 before and after ageing. X
19 Ageing tests on pieces of complete cable X
20 Loss of mass test on PVC Sheath X
21 Pressure test at high temperature on sheaths X
22 Tests on PVC Sheaths at low temperature X
23 Heat shock test for PVC Sheaths X
24 Carbon black content of PE Sheaths X
25 Shrinkage test for XLPE Insulation X
26 Test under fire conditions (if required) X
9
27 Water penetration test. X

10
 TECHNICAL DATA
66 kV
WIRES & CABLES

Polycab 66 KV, Single Core XLPE Cable with Copper / Aluminium

Conductor,Screened, XLPE Insulation, Lead alloy "E" Sheathed and Copper
Screened with PVC / PE Sheath
XLPE PVC/PE Weight of Weight of
Nominal Conduct Insulatio Lead Sheath COPPER ALUMINIU
Cross or n Sheath Copper Thickness Overall Cable M
Section of Diamete Thicknes Thickness Screen (Nominal) Dia of (Approx Cable
Conductor r s Area Cable .) (Approx
(approx. (Nominal .)
) )
Sq.mm mm mm mm Sq.mm mm mm kg/km kg/km
185 16.5 11 2.0 70 2.8 60 8850 7000
240 18.5 11 2.0 95 3.0 63 9700 8260
300 20.5 11 2.0 95 3.0 66 10900 9000
400 23.0 11 2.1 95 3.2 69 11400 9850
500 27.0 11 2.2 95 3.2 73 13000 10000
630 30.0 11 2.2 95 3.4 76 14900 11000
1000 39.5 11 2.4 95 3.6 85 18600 12500

66 kV Polycab 66 KV, Single Core XLPE Cable with Copper / Aluminium

Conductor, Screened, XLPE Insulation, Poly Al. Sheathed and Copper Screened with PVC / PE
Sheath
XLPE Weight of Weight of
Nominal Conduct Insulation PVC/PE COPPER ALUMINIU
Cross or Thickness Copper Sheath Overall Cable M
Section of Diamete (Nominal) Screen Thickness Dia of (Approx Cable
Conductor r Area Cable .) (Approx
(approx. .)
)
Sq.mm mm mm Sq.mm mm mm kg/km kg/km
185 16.5 11 70 2.8 39 5900 4850
240 18.5 11 95 2.8 51 6700 5150
300 20.5 11 95 3.0 64 7250 5500
400 23.0 11 95 3.0 66 8250 5800
500 27.0 11 95 3.2 71 9450 6500
630 30.0 11 95 3.2 74 10800 7000
1000 37.5 11 95 3.6 83 14700 8400

ELECTRICAL DATA
66 kV 1 CORE XLPE CABLES
Short Circuit
Conductor Resistance
Ohm/KM Capacity of Capacitance Inductanc Charging
Size Conductor. (Approx.) e Trefoil Current
At 20oC At 90oC kA / Sec. form - Rated
Voltage
Sq.mm Cu. Al. Cu. Al. Cu. Al. uF / km. mH / km. Amps/km.
185 0.0991 0.164 0.1272 0.210 26.5 17.6 0.17 0.45 2.0
240 0.0754 0.125 0.0973 0.161 34.5 22.7 0.18 0.43 2.2
300 0.0601 0.10 0.0781 0.129 42.9 28.3 0.20 0.42 2.4
1
1
 400 0.0470 0.0778 0.0619 0.1010 57.2 37.8 0.22 0.40 2.6
500 0.0366 0.0605 0.0493 0.0792 71.5 47.2 0.24 0.38 2.9
630 0.0283 0.0469 0.0395 0.0623 90.1 59.5 0.26 0.37 3.1
1000 0.0176 0.0291 0.0276 0.0410 143 94.5 0.31 0.35 3.7

12
WIRES & CABLES

TECHNICAL DATA
132 kV Polycab 132 KV, Single Core XLPE Cable with Copper / Aluminium
Conductor, Screened, XLPE Insulation, Lead alloy "E" sheathed and
Copper Screened with PVC / PE Sheath
Nominal XLPE Weight of Weight of
Cross Conduct Insulation PVC / HDPE Coppe COPPER ALUMINIU
Section or Thickness Lead Outer r Overall Cable M
of Diamete (Nominal) Sheath Sheath Scree Dia of (Approx Cable
Conductor r Thickness thickness n Area Cable .) (Approx
(approx. .)
)
Sq.mm mm mm mm mm Sq.mm mm kg/km kg/km

240 18.4 18 2.3 3.3 95 74 12300 10800

300 20.5 18 2.3 3.4 95 76 13400 11550

400 23.0 18 2.4 3.5 95 78 15600 13100

500 27.0 18 2.4 3.6 95 84 16800 12350

630 30.0 18 2.5 3.8 95 86 18500 14600

ELECTRICAL DATA
132 kV 1 CORE XLPE CABLES
Short Charging
Circuit Current -
Conductor Resistance Ohm/KM
Capacity Capacitanc Rated
Size At 20oC At 90oC of e Inductanc Voltage
Conductor. (Approx.) e
kA / Sec.
Sq.mm Cu. Al. Cu. Al. Cu. Al. uF / km. mH / km. Amps/km.

240 0.0754 0.125 0.0973 0.161 34.5 22.7 0.12 0.48 2.87

300 0.0601 0.10 0.0781 0.129 42.9 28.3 0.13 0.46 3.10

400 0.0470 0.0778 0.0619 0.1010 57.2 37.8 0.14 0.45 3.35

500 0.0366 0.0605 0.0493 0.0792 71.5 47.2 0.16 0.43 3.82

630 0.0283 0.0469 0.0395 0.0623 90.1 59.5 0.17 0.41 4.0

1000 0.0176 0.0291 0.0276 0.0410 143 94.5 0.21 0.37 5.0

11
WIRES & CABLES CABLE HANDLING
(Pre-Installation)

OVERVIEW
CABLE INSPECTION CABLE HANDLING
To ensure safety during cable
Inspect every cable reel for Remove all nails and staples
installation and reliability once the
damage before accepting the from the reel flanges before
cable is installed, user should
shipment. Be particularly moving a reel, and avoid all
confirm the following prior to
alert for cable damage if: objects that could crush,
installation.
damage or impact the cable
 The cable selected is proper  A reel is laying flat on its when moving. NEVER use
for designed application. side the cable as a means to
 Several reels are stacked move a reel.
 The cable has not been
damaged in transit or storage.  Other freight is stacked on
a reel When unreeling, observe
Review all applicable state and recommended bending radii,
 Nails have been driven into use swivels to prevent
national codes to verify that the
reel flanges to secure twisting and avoid overruns.
cable chosen is appropriate for
shipping blocks
the job. Also, consult your local
electricity authority / consultant.  A reel flange is damaged
 A cable covering is
Next, you must identify any removed, stained or
existing cable damage and damaged
prevent any further damage from
 A cable end seal is
occurring. This is done through
removed or damaged A
proper cable inspection, handling
reel has been dropped
and storage.
(hidden damage likely)

STORAGE: 3. It is recommended to avoid stored cables

In general, the requirements for cable storage are immediately prior to installation in direct
quite straight forward. Maintain the cable dry, at a sunlight when ambient temperatures are
temperature that will not cause degradation, and in excess of 122°F or 55oC. Some jackets
protect the cable from damage. will soften and this may lead to physical
damage during installation.
In order to maintain cable dryness, it is mandatory
that the following steps be taken: 4. When cable is stored at temperatures
below 0°C, it is necessary to move the
1. Maintain cable and end cap moisture seal reel(s) into a heated area before
integrity. installation, maintained at a minimum
temperature above 5oC. The cable must
2. Do not store in locations where standing reside in this heated area for at least 8
water is likely. hours before it is installed.

3. Maintain cable ends fixed to reel flanges In order to protect the cable from damage, it is
without puncturing jackets of end caps. necessary to:

In order to keep the cable from degrading and 1. Store cable, especially long-term storage, in
ready for use, it is necessary to: relatively inactive areas.

1. Maintain, as far as practicable, a covering 2. Maintain a covering on the cable reels to

over the cable on the reel. avoid cable sheath damage.

2. Maintain storage temperatures above 5°C. 3. In areas of extreme rodent infestation,

Storing below 5oC for long period can cables should be protected with full lagging,
cause damage to sheath. Consult cable steel plates over flange penetrations or
manufacturer in such events. other suitable means.

12
Store cable reels standing on flange rims.
DO NOT, except in special circumstances,
store cable reels on their sides; i.e., lying on
one or the other flange.

13
WIRES & CABLES

RECOMMENDED CABLE HANDLING PROCEDURES

Wire and Cable Reel Handling and Storage

When off loading reels from a truck, lower reels carefully using a hydraulic
gate, hoist or forklift truck. Never drop reels. If reels must be rolled, roll in
opposite direction of the cable wraps to keep cable from loosening on the reel.
DON’T

When using a hoist, install a mandrel through the reel arbor holes and
attach a sling. Use a spreader bar approximately 6 inches longer than the
overall reel width placed between the sling ends just above the reel flanges.
This will prevent bending the reel flanges and mashing the cable DO DON’T

If a fork lift is used, approach the reel from the flange side.
Position the forks such that the reel is lifted by both reel flanges.
Do not allow the lift forks to contact the cable. Care must be taken by
the fork lift operator not to make sudden turns or stops.
DO DON’T

When selecting a storage site, consideration should be given to:

 Traffic patterns during off-loading
 Grade and condition of the soil or pavement
 Protection from vehicle damage during the time in storage
 Environmental conditions such as exposure to heat, corrosive chemicals, etc.

Cable reels should be stored on hard surfaces resting on the

flanges edge (flanges vertical). Align reels flange to flange and, if
possible, arrange so that first in is first out. Multiple reels stacked
on top of each other (“Pancake” storage), or storing reels flat
(flanges horizontal) is not recommended for bare conductor or
medium voltage cable. The weight of the stack can total
thousands of kgs. creating an enormous load on the bottom reel.
DON’T Also, damage to the reel and/or cable will likely occur when the
reel is flipped for transit. A concentration of stress on the reel
flange may cause it to break and subsequently damage the
cable.

13
WIRES & CABLES

CURRENT RATINGS

66 kV COPPER XLPE CABLES WITH LEAD

SHEATH
Reactance Continuous Current Continuous Current
Size of Cable Rating in Ground Rating in Air
Trefoil Flat Trefoil Flat Trefoil Flat

185 0.137 0.215 360 370 520 570

240 0.131 0.205 410 430 605 670
300 0.126 0.198 460 485 690 765
400 0.122 0.190 515 550 860 885
500 0.118 0.182 580 625 910 1020
630 0.112 0.173 645 705 1025 1175

66 kV ALUMINIUM XLPE CABLES WITH LEAD SHEATH

Reactance Continuous Current Continuous Current

Size of Cable Rating in Ground Rating in Air
Trefoil Flat Trefoil Flat Trefoil Flat

185 0.137 0.215 280 292 400 465

240 0.131 0.205 320 337 470 520
300 0.126 0.198 355 379 532 590
400 0.122 0.190 412 430 625 695
500 0.118 0.182 465 493 724 805
630 0.112 0.173 520 562 830 940

Current Ratings are based on the following conditions:

a) Single point bonding / cross bonding.

b) Ground temperature : 30oC.
c) Max. Conductor temperature : 90oC
d) Ambient Air Temperature : 40oC
e) Depth of laying : 150 cm.

14
WIRES & CABLES
66 & 132 kV XLPE CABLES ACCESSORIES,
JOINTING, TERMINATIONS AND
INSTALLATION
Accessories are the integral part of power transmissions through cables. The design
concept of XLPE cable must take into consideration the demands of such
application.

Polycab can source out a full range of accessories to cover all types of jointing
requirements and terminations. These accessories meet all international
standards and have proven reliability for many years of operation.

Jointing

TERMINATION STRAIGHT THROUGH JOINT

RATING FACTORS
Rating Factors for Variation in Ambient Temperature (Air/Ground)
(Max. Conductor Temperature 90oC)

Temperature oC 15 20 25 30 35 40 45 50 55 60
Rating Factor in Air 1.25 1.20 1.16 1.11 1.05 1.00 0.94 0.88 0.82 0.76
Rating Factor in Ground 1.12 1.08 1.04 1.00 0.96 0.91 0.87 0.82 - - --

Group Rating Factors for Groups of Cables in Ground

Number of Circuits in Group
Distance between
centres of circuits
mm 1 2 3 4 5 6 7 8 9
100 1 0.75 0.64 0.60 0.53 0.50 0.50 0.48 0.45
200 1 0.80 0.70 0.60 0.60 0.57 0.56 0.53 0.52
400 1 0.83 0.75 0.70 0.68 0.65 0.64 0.63 0.62
600 1 0.86 0.80 0.75 0.75 0.70 0.71 0.70 0.70
800 1 0.88 0.85 0.80 0.80 0.77 0.76 0.75 0.74
2000 1 0.95 0.92 0.90 0.90 0.91 0.90 0.90 0.89

15
WIRES & CABLES

Rating Factor for Phase Spacing in Flat Formation

Phase Spacing (S) mm D D+70 200 250 300 350 400

Rating Factor 0.93 1.00 1.03 1.05 1.07 1.08 1.10

Rating Factor for Thermal Resistivity of Soil

Soil Thermal Resistivity

Deg. C.cm / Watt 70 100 120 150 200 250 300
Rating Factor 1.36 1.18 1.10 1.00 0.88 0.73
0.78
Rating Factor for Depth of Laying

Depth of laying - 90 100 120 150 160 170 180 190 200
cm
Rating Factor 1.06 1.05 1.03 1.00 0.99 0.99 0.98 0.98 0.97

Electric potential are induced in cable sheath by

electromagnetic induction. The permissible
voltage rise has to be restricted to 60 volts are per
P&T regulation to avoid interference with
communication lines. Methods are available to
reduce sheath voltages and currents and our
recommendations for this system is given below:

METHODS:
Single Point Bonding
This is applicable for short cable circuit, such as
interconnection with sub-stations or termination
of an overhead line into a sub-station. In this
system, the three sheaths are bonded and earthed
at one of the cable route. Hence,
 A voltage will appear from sheath to earth which
will be maximum at the farthest point from the
earth bond at other end.
 No induced current hence, no sheath losses result.

The effects of Design Variation:

The tabulated data has been calculated carefully considering standard site conditions. However, the
design changes can affect the cable characteristics, hence, the declared data is for guidance only
and shall not be considered as guaranteed.
16
WIRES & CABLES

Mid Point Bonding: Cross Bonding:

This is a modification of the single point bonding This is applicable for longer circuit. In this
method whereby the circuit is effectively split up system, the sheaths of the adjoining cables are
into two elementary sections. By Mid Point connected in a manner so as the sheaths are
Bonding, the length of the cable circuit can be electrically 120o apart.
increased to almost twice that of Single Point
Bonded system. In this system, the three sheaths Cross-bonding essentially consists of
are bonded and earthed at the center of the cable sectionalizing the sheaths into minor sections
route. As a result: which are cross bonded. The minor sections
together make a major section.
 Voltage will appear from sheath to earth which
will be maximum at both ends of the cable route. For cables in trefoil formation, their sheath
voltage under the cross bonded system will be
 No induced current, hence, no sheath losses result.
equal across a major section and have a phase
displacement of 120o (by ensuring the minor
Both Ends Bonded: sections have identical lengths). The vector sum
of the voltage will be zero. Hence, eliminating
This is applicable for long circuit lengths. In this circulating current and sheath losses.
system, the sheaths are bonded and earthed at both
the ends of the cable. As a result of the flow of This system however have the following
sheath currents sheath losses take place which disadvantages:
slightly derates the current rating. This system has
the following distinct advantages:  Complexity of the system

 Maintenance of the link boxes (prevention

There is no sheath voltage to earth hence, ensures
of water seepage to be ensured).
safety.
 Higher capital cost.
Installation is simple, and no maintenance or
monitoring of the installation is necessary.

● ● ● ● ●

17
 ©

WIRES & CABLES

PVC INSULATED
HEAVY DUTY
CABLES
1100 V.
Details make the Difference IS 1554 (Part I)

19
P R O D U C T R A N G E

■
L.T. PVC & XLPE POWER CABLES WITH
COPPER / ALUMINIUM CONDUCTOR (1100 V.
UPTO 4 CORE X 630 SQ. MM., 1 CORE X
1000 SQ. MM.)
■
L.T PVC & XLPE CONTROL CABLES
(1100 V. UPTO 61 CORE X 1.5 & 2.5 SQ.MM.)
■
H.T. XLPE CABLES UPTO 132 kV
■
FIRE SURVIVAL, ZERO HALOGEN CABLES
■
THERMO COUPLE COMPENSATING & EXTENSION
CABLES
■
INSTRUMENTATION CABLES SCREENED /
UNSCREENED
■
FRLS / FR / HR / HFFR / HOFR / RUBBER –
POWER, CONTROL & INSTRUMENTATION
CABLES
■
HT / LT AERIAL BUNCHED CABLES
■
RAILWAY SIGNALLING CABLES
■
TELEPHONE CABLES – DRY & JELLY FILLED
■
ACSR & AAAC CONDUCTORS
■
MINING / WELDING – RUBBER CABLES
■
EPR / SILICONE / HIGH TEMP. CABLES
■
SUBMERSIBLE CABLES
■
COAXIAL CABLES
■
BUILDING WIRES & FLEXIBLES (SINGLE &
MULTICORE)
■
LAN CAT-5 / 5E, 6 CABLES
■
PVC PIPES & ACCESSORIES
■
INDUSTRIAL PLUGS & SOCKETS
 ©

Contents
AN ISO 9001:2000 COMPANY

Details make the difference 2

Introduction 3-5

Tables 6-21

Rating Factors 22-24

Selection of Cables & FRLS 25

Short Circuit Rating 26

Handling 27-28

1
Details make the difference

THE COMPANY from its

POLYCAB, an ISO 9001: 2000 company customers.
is the largest Wire & Cable The growth
manufacturer in India with a proven of the latter
track record of over three decades. is a
The fastest growing company in the
Indian Cable Industry with
consistent growth of more then
40% per annum for the last 4 years.
Polycab group has crossed Rs. 2000
crore turnover in the year 2006- 07
and is set to achieve Rs. 3000 crore
turnover in the year 2007 – 08.
From a modest beginning with
Wires and Cables, over three
decades ago Polycab set up State of
Art manufacturing facilities at
Daman in 1996.The last 3
decades have seen the core
business develop along different
product lines: - Low Voltage
Cables, Medium Voltage Cables,
Extra High Voltage Cables, Fire
Survival & Fire Resistant Cables,
Telecommunication Cables,
Instrumentation Cables and Aerial
Bunched Cables. In the
manufacture of cables, a
competitive edge lies not so much
in product innovation as in providing
consistent quality, guaranteeing
reliability and ready availability.
Polycab’s Daman factory was
created to address these key
market determinants. The
manufacturing set up is sourced
out from the world renowned
Machinery and Technology
suppliers with constant upgradation
and expansions.
CUSTOMER SATISFACTION
In an on going process to improve
Customer Satisfaction Polycab
offers a variety of services:
• Commercially competitive prices.
• Reliable & consistent quality.
• Reliable & just in time delivery.
• Product development for a
changing market.
• A targeted stocking policy.
• Technical Support for
Applications/ Projects

CUSTOMER FOCUSED
POLYCAB derives its strength
prerequisite to the growth of the company and hence Utilities, The Titans of Indian
customers’ satisfaction is its prime objective. Over the Industry & Consultants / Specifiers.
years sincere service and dedication to its Customers
has earned the Company distinguished Customers DETAILS MAKE THE DIFFERENCE
which includes demanding leaders in Sectors like More than 3 decades of experience
Utilities, Power Generation, Transmission & Distribution, have enabled POLYCAB to
Petroleum & Oil Refineries, Oem’s, EPC contractors, develop a specific know how for
Steel & Metal, Cement, Chemical, Atomic Energy, Nuclear each individual productline.
Power, Consultants & Specifiers etc. Attention to details allows the
company to apply optimum
POLYCAB has highly experienced qualified and dedicated
technical solutions and material
professionals with strong adherence to the quality
selections to each and every
management system. Polycab has offices all over the
different project or application.
country and also has a wide network of authorized
distributors and dealers to cater to all the customer segments Other available Catalogues:
in India and abroad. Flexible Cables
POLYCAB has earned the trust and reputation in India and LT XLPE Power &
abroad by winning the customers’ confidence. Several Control. HT Cables
thousands kilometers of LT PVC Cables in the voltage range upto 45KV EHV
of 1.1KV have been manufactured and are in operation in
Cables upto 132Kv
India and abroad.
Fire Survival Cables.
Polycab LT PVC Cables are preferred choice in Power Plants,
Distribution Systems, Heavy Industries, Various

Polycab Wires Pvt. Ltd. takes every precaution to ensure the information given in this publication
is correct. E & O.E. all information is subject to change without notice.

2
 ©

PVC insulated LT Heavy Duty cables

are as per IS-1554 (Part I) 1988 and are suitable for fixed
installations. AN ISO 9001:2000
COMPANY

The cables are suitable for use on I.S. 1554

AC single phase or three phase permits solid
(earthed or unearthed) systems for conductor
rated voltage up to and including construction
1100 volts. These cables can be used upto 10
on DC systems for rated voltage up to sq.mm in
and including 1500 volts to earth. Aluminium
and upto 6
CONDUCTOR sq.mm in
The most acceptable metals for copper. It
conductors are copper and permits the
aluminium due to their higher use of shaped
conductivity and ductility. conductors for
sizes from 16
As copper has got higher affinity for sq.mm
sulphur, it corrodes in the atmosphere onwards.
where sulphur fumes are present. In
these conditions tinned copper INSULATI
should be used. Aluminium oxide ON
film which is always present on
Aluminium conductor surface acts as The PVC
barrier and it protects the Aluminium covering over
conductor from corrosion in fumes conductor is
laden atmosphere. called
insulation
CONDUCTOR CONSTRUCTION and is
provided by
The most economical construction extrusion
for conductor is solid conductor i.e.
process only.
conductor is made of one single
The
wire. As the area of conductor
insulated
increase, solid conductor becomes
conductor is
more stiff and hence difficult to
called core.
handle. In this case stranded
construction is adopted. Here the
conductor is made of number of
strands. The strands are arranged in
spiral layers in 1+6+12+18+…
formations. This
construction provides more flexibility.
Where crimping of lugs are required, the
conductor has to be of stranded
construction only.
To economise in insulating material,
weight and overall diameter,
shaped conductors are employed in
bigger sized cables. Here the
stranded conductor is shaped in to
a segment of a circle so that when
all the cores are laid, they form a
complete circle. These segments are
identified as 2 Core
– 180 degree, 3 Core – 120 degree,
4 Core
– 90 degree and 3.5 Core – 100/60
degree.

3
I.S. 1554 permits two types of PVC insulation as follows
:
1) Insulation with TYPE A PVC compound as per I.S. 5831
which is suitable for 70 deg.C continuous operation.
2) Insulation with TYPE C PVC compound as per I.S. 5831
which is suitable for 85 deg.C continuous operation.
The following colour code is used for identification :
Single Core : Red, Black, Yellow or Blue. Two Cores :
Red and Black
Three Cores : Red, Yellow and Blue.
Three & Half : Red, Yellow, Blue and
Reduced neutral Black.
Four Core : Red, Yellow, Blue and Black. Five Core : Red,
Yellow, Blue, Black, & Grey Six Cores : Two adjacent cores.
Blue and Yellow
(Counting and direction core) And remaining Grey in
each layer. OR By printing numbers on each
core.

LAYING UP
The cores are laid up with suitable lay. The final layer always
has a right hand lay i.e. if you look along the cable, the cores
move to your right hand.

INNERSHEATH
Innersheath is provided over the laid up cores. It is
provided to give circular shape to the cable and it provides
bedding for the armouring.
I.S. 1554 permits following two methods of applying
the innersheath of any thermoplastic material i.e. PVC,
Polyethylene, etc.
a) EXTRUDED INNERSHEATH: Here
the innersheath is provided by extrusion of Thermoplastic
over the laid up cores. This type of the innersheath is
generally provided in cables having round cores i.e in control
cables and in power cables upto 10 sq.mm size. This type
of the innersheath also acts as a water barrier between
cores
 ©

PVC insulated LT Heavy Duty cables

are as per IS-1554 (Part I) 1988 and are suitable for fixed installations.
installations. AN ISO 9001:2000
COMPANY

and outersheath. In case of a of earth

puncture in the outersheath the fault.
water can not reach to the cores
In mines,
and hence we recommend that
the
cables for outdoor underground
resistance
uses should have extruded
of the
innersheath.
armour in
b) TAPPED INNERSHEATH: Here no case
the should
innersheath is provided by exceed the
wrapping a thermoplastic tape resistance
over the laid up cores. It is of the main
generally employed in cables having core by more
sector shaped cored i.e. multicore than 33% for
cables of 16 sq.mm and above. safety
reasons. To
This method saves a process and
achieve this,
hence manufacturers always
sometimes
provide this type of innersheath
tinned hard
unless the purchase specifications
drawn copper
ask for extruded innersheath.
wires are
ARMOURING required to
be
In case of armoured cables,
generally galvanized steel wire /
strip armouring is provided over 4
the innersheath in multi- core
cables and Aluminium Round Wire
or Aluminium Strip over the
insulation in single core cables. It
provides mechanical protection to
inside cores and it carries earth
return current in case of a short
circuit of a core with armour.
As per I.S. 1554 (Part I) 1988,
round wire armouring is provided
in cable, where calculated diameter
under armour is upto 13 mm. Above
this the armouring is either with round
wire or strip of size 4 mm x 0.80
mm. As strip construction is
economical, the manufacturers
always provide steel strip
armouring unless wire armouring
is specially specified.
In long run of cables and in case of
mines, round wire armouring is
must, as strip construction
provides higher resistance to earth
fault current and sometimes this
current may not be sufficient to 5
operate the circuit breaker in case
used along with galvanized steel wires. Sometimes two
layers of Round Steel Wire or Steel Strip are applied in
opposite direction with barrier tape in between are provided
to give extra protection.
In case of single core armoured cables for use in AC
circuits, the material for armouring has to be non
magnetic, as in this case the return current is not passing
through the same cable and hence it will not cancel the
magnetic lines produced by the current. These magnetic lines
which are oscillating in case of AC current will give rise to
eddy current in magnetic armouring and hence armouring will
become hot, and this may lead to the failure of the cable.
Generally hard drawn aluminium wires / strip are used for
armouring in this case.

OUTERSHEATH
The PVC covering over the armouring in case of
armoured cables and over the innersheath in case of
unarmoured cables is called outersheath.
I.S. 1554 specifies nominal and minimum thicknesses of
outer sheath for unarmoured cables and only minimum
thickess of outer sheath for armoured cables.
It permits the following types of outer sheath PVC
compounds.
1) Outer sheath with type ST1 PVC compound as per IS-
5831, which is suitable for 70°C continuous
operation.
2) Outer sheath with Type ST2 PVC compound as per
IS-5831, which is suitable for 85°C continuous
operation.
PVC has got fire retardant properties due to its halogen
content. The fire in the cable gets extinguished immediately
on removal of the fire source.
In the modern Power, Chemical, Fertilizer and Cement Plants
many PVC cables are bunched in the cable shaft or on
cable trays. In case of fire in these cables, the fire
becomes self sustaining. Moreover due to the burning of
PVC a dense corrosive
 ©

PVC insulated LT Heavy Duty cables

are as per IS-1554 (Part I) 1988 and are suitable for fixed
installations. AN ISO 9001:2000
COMPANY

smoke is emitted which makes fire If required, we can provide Fire

fighting very difficult, due to poor
Retardant Low Smoke (FRLS) PVC
visibility and toxic nature of the
smoke. HCL content of the smoke, Inner sheath and / or outer sheath.
not only damages other costly This PVC compound, apart from
equipment lying nearby, but also meeting the requirements of Type ST2
penetrates the RCC and corrodes the as per IS-5831, has got better fire
steel reinforcement. Due to this retardant properties and it emits
there is an extensive damage to
lower smoke and acid fumes when it
the property.
catches fire. (For more information
To overcome these deficiencies FRLS
please refer our catalogue on FRLS
i.e. Fire Retardant Low Smoke PVC
was developed. cables).

CABLE CODE
The following codes are used for designating the cables as per IS-1554.
CONSTITUENT CODE LETTER
COPPER CONDUCTOR —
ALUMINIUM CONDUCTOR A
PVC INSULATION Y
STEEL ROUND WIRE W
ARMOUR
STEEL STRIP ARMOUR F
STEEL DOUBLE ROUND WIRE W
ARMOUR
STEEL DOUBLE STRIP ARMOUR W
FF
PVC OUTER Y
SHEATH
YWY means Copper conductor, PVC insulated, round wire armoured and PVC sheathed
cable. AYFY means Aluminium conductor, PVC insulated, steel strip armoured and PVC
sheathed cable.

EXAMPLES 1 core of 25
3 Core x 2.50 sq.mm YWY : Plain sq.mm
Copper conductor, PVC insulated, laid conductor
up, innersheathed, G.I. wire size.
armoured and PVC sheathed cable The
having 3 cores of 2.50 sq.mm following
conductor size. tables give
4 core x 4.0 sq.mm AYWY: construction
Aluminium conductor, PVC details of
insulated, laid up, innersheathed, Polycab
G.I. wire armoured and PVC cables as
sheathed cable having 4 cores of per IS: 1554
4.0 sq.mm conductor size. ({Part I)
1988.
3 ½ core x 50 sq.mm AYFY:
Aluminium conductor, PVC For current
insulated, laid up, innersheathed, rating of
Steel strip armoured and PVC sheathed Polycab
cable having 3 cores of 50 sq.mm and cables with

5
H.R. insulation increase the rating
given in the following tables by 15%.
The weights of the cables mentioned
in the following tables are
approximate and given for guidance
only. They should never be used as
criteria to check the lengths of the
cables supplied. The best way to
check the length of the supplied
cable is by resistance method. Take
the resistance of the full drum and
divide the reading by the resistance
of 1 mtr. length.
To decide the size of the
conductor, particularly that of the
sector shaped conductor, we
recommend the following method.
Take weight of a small conductor
piece and measure its weight in
grams. Then find out the weight of
the conductor in gms per meter
length. Divide it by 2.7 in case of
Aluminium and by 8.9 in case of
copper. It will give the area of the
conductor in sq.mm.
 ©

Weight, Dimension
PVC insulated data Duty
LT Heavy & cables
Current
are carrying capacity
as per IS-1554 (Part I) 1988of cables
and are suitable for fixed
installations. AN ISO 9001:2000
COMPANY

TABLE-1 “POLYCAB” 1.1 KV SINGLE CORE, ALUMINIUM CONDUCTOR, PVC INSULATED ALUMINIUM WIRE / STRIP
ARMOURED & PVC SHEATHED CABLES CONFORMING TO IS:1554 (PART I) AMENDED UPTO DATE

Nominal Nominal Armour Nomina Approx Approx. Max. Dc Current Ratings

Cross Thickness Aluminiu Aluminiu l . Weight of Conductor Direct In Ground In Duct In Air
Sectional of m Wire m Strip Thicknes Overall Cable Resistance
2 Cables 3 Cables 2 Cables 3 Cables 2 Cables 3 Cables
Area Insulation Dia Thicknes s of Diamete at 20°C
s Outer r
Sheath
Sq.mm mm mm mm mm mm kg/mm Ohm/Km Amps Amps Amps Amps Amps Amps
*4 1.3 1.4 - 1.24 11.0 155 7.410 36 31 33 30 32 27
*6 1.3 1.4 - 1.24 12.0 175 4.610 44 39 42 37 41 35
*10 1.3 1.4 - 1.24 13.0 205 3.080 50 51 56 51 56 47
16 1.3 1.4 - 1.24 14.0 230 1.910 75 66 71 65 72 64
25 1.5 1.4 - 1.24 15.0 300 1.200 97 86 93 84 99 84
35 1.5 1.4 - 1.24 16.0 350 0.868 97 100 110 100 120 105
50 1.7 1.4 - 1.24 18.0 430 0.641 120 120 130 115 150 130
70 1.7 1.4 - 1.40 20.0 530 0.443 145 140 155 135 185 155
95 1.9 - 4 x 0.80 1.40 21.0 610 0.320 170 175 180 155 215 190
120 1.9 - 4 x 0.80 1.40 22.0 710 0.253 205 195 200 170 240 220
150 2.1 - 4 x 0.80 1.40 24.0 840 0.206 230 220 220 190 270 250
185 2.3 - 4 x 0.80 1.40 26.0 1020 0.164 265 240 240 210 305 290
240 2.5 - 4 x 0.80 1.40 29.0 1250 0.125 300 270 270 225 350 335
300 2.7 - 4 x 0.80 1.56 32.0 1500 0.100 335 295 295 245 395 380
400 3.0 - 4 x 0.80 1.56 36.0 1910 0.078 370 325 335 275 455 435
500 3.4 - 4 x 0.80 1.56 40.0 2350 0.061 410 345 355 295 490 480
630 3.9 - 4 x 0.80 1.72 44.0 2920 0.047 435 390 395 320 560 550
800 3.9 - 4 x 0.80 1.88 48.0 3510 0.037 525 440 420 350 650 640
1000 3.9 - 4 x 0.80 2.04 53.0 4300 0.029 570 490 445 380 735 720
* If required, these sizes can be offered with stranded conductors also

TABLE 2 “POLYCAB” 1.1 KV SINGLE CORE, ALUMINIUM CONDUCTOR, PVC INSULATED

UNARMOURED PVC SHEATHED CABLES CONFORMING TO IS:1554 (PART I) AMENDED UPTO DATE
Nominal Nominal Nomina Approx Approx. Max. Dc Current Ratings
Cross Sec- Thickness l . Weight of Conductor Direct In Ground In Duct In Air
tional Area of Thicknes Overall Cable Resistance
Insulation s of Diamete at 20°C 2 Cables 3 Cables 2 Cables 3 Cables 2 Cables 3 Cables
Outer r
Sheath
Sq. mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps. Amps. Amps. Amps.
*1.5 0.8 1.8 7.0 55 18.100 21 17 19 17 18 15
*2.5 0.9 1.8 7.5 65 12.100 28 24 25 24 25 21
*4.0 1.0 1.8 8.0 75 7.410 36 31 33 30 32 27
*6.0 1.0 1.8 9.0 90 4.610 44 39 42 37 41 35
*10 1.0 1.8 10.0 105 3.080 54 51 56 51 56 47
16 1.0 1.8 11.0 140 1.910 75 66 71 65 72 64
25 1.2 1.8 12.5 195 1.200 97 86 93 84 99 84
35 1.2 1.8 13.5 235 0.868 120 100 110 100 120 105
50 1.4 1.8 15.0 305 0.641 145 120 130 115 150 130
70 1.4 1.8 17.0 385 0.443 170 140 155 135 185 155
95 1.6 1.8 19.0 515 0.320 205 175 180 155 215 190
120 1.6 2.0 21.0 610 0.253 230 195 200 170 240 220
150 1.8 2.0 22.5 735 0.206 265 220 220 190 270 250
185 2.0 2.0 25.0 885 0.164 300 240 240 210 305 290
240 2.2 2.0 28.0 1100 0.125 335 270 270 225 350 335
300 2.4 2.0 30.0 1335 0.100 370 295 295 245 395 380
400 2.6 2.2 34.0 1665 0.078 410 325 335 275 455 435
500 3.0 2.2 38.0 2130 0.061 435 345 355 295 490 480
630 3.4 2.4 43.0 2685 0.047 485 390 395 320 560 550
800 3.4 2.4 47.0 3255 0.037 525 440 420 350 650 640
1000 3.4 2.6 51.5 3960 0.029 570 490 445 380 735 720 7
 * If required, these sizes can be offered with stranded conductors also

6
 ©

Weight, Dimension data &

Current carrying capacity of
cables AN ISO 9001:2000
COMPANY

TABLE-3 “POLYCAB” 1.1 KV SINGLE CORE, COPPER CONDUCTOR, PVC INSULATED ALUMINIUM WIRE / STRIP
ARMOURED & PVC SHEATHED CABLES CONFORMING TO IS:1554 (PART I) AMENDED UPTO DATE

Nominal Nominal Armour Nomina Approx Approx. Max. Dc Current Ratings

Cross Thicknes Aluminiu Aluminiu l . Weight of Conducto Direct In Ground In Duct In Air
Sectional s of m Wire m Strip Thicknes Overall Cable r
Area Insulation Dia s of Diamete Resistanc 2 Cables 3 Cables 2 Cables 3 Cables 2 Cables 3 Cables
Thicknes
s Outer r e at
Sheath 20°C
Sq. mm mm mm mm mm mm Kgs/Km Ohm/Km Amps. Amps. Amps. Amps. Amps. Amps.
*4 1.3 1.4 - 1.24 11.0 180 4.610 46 39 42 38 43 35
*10
*6 1.3
1.3 1.4
1.4 -- 1.24
1.24 13.0
12.0 270
215 1.830
3.080 75
57 65
49 72
54 64
48 72
54 60
44

25
16 1.5
1.3 1.4
1.4 -- 1.24
1.24 15.0
14.0 460
330 0.727
1.150 125
94 110
85 120
92 110
83 125
92 110
82

35 1.5 1.4 - 1.24 16.0 575 0.524 150 130 140 125 155 130
50 1.7 1.4 - 1.24 18.0 740 0.387 180 155 165 150 190 165
70 1.7 1.4 - 1.40 20.0 970 0.268 220 190 200 175 235 205
95 1.9 - 4 x 0.80 1.40 21.0 1200 0.193 265 220 230 200 275 245
120 1.9 - 4 x 0.80 1.40 22.0 1460 0.153 300 250 255 220 310 280
150 2.1 - 4 x 0.80 1.40 24.0 1770 0.124 340 280 280 245 345 320
185 2.3 - 4 x 0.80 1.40 26.0 2170 0.099 380 305 305 260 390 370
240 2.5 - 4 x 0.80 1.40 29.0 2740 0.075 420 345 340 285 445 425
300 2.7 - 4 x 0.80 1.56 32.0 3360 0.060 465 375 370 310 500 475
400 3.0 - 4 x 0.80 1.56 36.0 4400 0.047 500 400 405 335 570 550
500 3.4 - 4 x 0.80 1.56 40.0 5450 0.037 540 425 430 355 610 590
630 3.9 - 4 x 0.80 1.72 44.0 6820 0.028 590 470 465 375 680 660
* If required, these sizes can be offered with stranded conductors also

TABLE-4 “POLYCAB” 1.1 KV SINGLE CORE, COPPER CONDUCTOR, PVC INSULATED

UNARMOURED PVC SHEATHED CABLES CONFORMING TO IS:1554 (PART I) AMENDED UPTO DATE

Nominal Nominal Nomina Approx Approx. Max. Dc Current Ratings

Cross Sec- Thickness l . Weight of Conductor Direct In Ground In Duct In Air
tional Area of Thicknes Overall Cable Resistanc
Insulation s of Diamete e at 2 Cables 3 Cables 2 Cables 3 Cables 2 Cables 3 Cables
Outer r 20°C
Sheath
Sq. mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps. Amps. Amps. Amps.
*1.5
*4.0 0.8
1.0 1.8
1.8 7.0
8.0 65
100 12.100
4.610 25
46 22
39 23
42 21
38 24
43 20
35
*2.5 0.9 1.8 7.5 82 7.410 35 30 31 29 32 27
*10 1.0 1.8 10.0 170 1.830 75 65 72 64 72 60
*6.0 1.0 1.8 9.0 130 3.080 57 49 54 48 54 44
25 1.2 1.8 12.5 350 0.727 125 110 120 110 125 110
16 1.0 1.8 11.0 240 1.150 94 85 92 83 92 82

35 1.2 1.8 13.5 455 0.524 150 130 140 125 155 130

70 1.4 1.8 17.0 820 0.268 220 190 200 175 235 205

120 1.6 2.0 21.0 1355 0.153 300 250 255 220 310 280

185 2.0 2.0 25.0 2040 0.099 380 305 305 260 390 370

300 2.4 2.0 30.0 3200 0.060 465 375 370 310 500 475

7
 150 1.8 2.0 22.5 1665 0.124 340 280 280 245 345 320

240 2.2 2.0 28.0 2590 0.075 420 345 340 285 445 425

400 2.6 2.2 34.0 4150 0.047 500 400 405 335 570 550
500 3.0 2.2 38.0 5230 0.370 540 425 430 355 610 590
630 3.4 2.4 43.0 6600 0.280 590 470 465 375 680 660
* If required, these sizes can be offered with stranded conductors also
 ©

Weight,Dimension
Weight, Dimensiondata
data&&
Current carrying capacity of cables
cables AN ISO 9001:2000
COMPANY

TABLE-5 “POLYCAB” 1.1 KV TWIN CORE, ALUMINIUM CONDUCTOR, PVC INSULATED, INNER SHEATHED,
ARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE

Nominal Nominal Nomina Armour Minimu Approx Approx. Max. Dc Current Ratings
Cross Thickness l Galv. Galv. Flat m . Weight of Conductor Direct In In Air
Sectional of Thicknes Round Steel Strip Thicknes Overall Cable Resistance In Ducts
Area Insulation s of Steel Wire Nominal s of Diamete at 20°C Ground
Inner Nominal Thickness Outer r
Sheath Dia. Sheath
Sq. mm mm mm mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps.
*1.5 0.8 0.3 1.4 - 1.24 12.5 320 18.100 18 16 16
*2.5 0.9 0.3 1.4 - 1.24 13.5 380 12.100 25 21 21
*4.0 1.0 0.3 1.4 - 1.24 15.0 450 7.410 32 27 27
*6.0 1.0 0.3 1.4 - 1.24 16.0 500 4.610 40 34 35
*10 1.0 0.3 1.4 - 1.24 18.0 600 3.080 55 45 47
16 1.0 0.3 - 0.8 1.40 18.0 500 1.910 70 58 59
25 1.2 0.3 - 0.8 1.40 20.0 650 1.200 90 76 78
35 1.2 0.3 - 0.8 1.40 21.5 750 0.868 110 92 99
50 1.4 0.3 - 0.8 1.40 24.5 950 0.641 135 115 125
70 1.4 0.3 - 0.8 1.56 28.0 1150 0.443 160 140 150
95 1.6 0.4 - 0.8 1.56 31.0 1460 0.320 190 170 185
120 1.6 0.4 - 0.8 1.56 33.0 1670 0.253 210 190 210
150 1.8 0.4 - 0.8 1.72 37.0 2010 0.206 240 210 240
185 2.0 0.5 - 0.8 1.88 40.5 2450 0.164 275 240 275
240 2.2 0.5 - 0.8 2.04 45.0 2950 0.125 320 275 325
300 2.4 0.6 - 0.8 2.20 50.0 3560 0.100 355 305 365
400 2.6 0.7 - 0.8 2.36 56.0 4500 0.078 385 345 420
500 3.0 0.7 - 0.8 2.68 62.5 5600 0.061 410 370 450
* If required, these sizes can be offered with standard conductors also

TABLE-6 POLYCAB 1.1 KV TWIN CORE, ALUMINIUM CONDUCTOR, PVC INSULATED, INNER SHEATHED,
UNARMOURED, PVC SHEATHED CABLES CONFORMING TO IS: 1554 (PART I) AMENDED UPTO DATE.

Nominal Nominal Nominal Nominal Approx Approx. Max. Dc Current Ratings

Cross Thickness of Thickness of Thickness . Weight of Conductor Direct In Ducts In Air
Sectional Insulation Inner of Outer Overall Cable Resistance In
Area Sheath Sheath Diamete at 20°C Ground
r
Sq. mm mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps.
*1.5 0.8 0.3 1.8 11.0 115 18.100 18 16 16
*2.5 0.9 0.3 1.8 12.0 150 12.100 25 21 21
*4.0 1.0 0.3 1.8 13.5 185 7.410 32 27 27
*6.0 1.0 0.3 1.8 14.5 220 4.610 40 34 35
*10 1.0 0.3 1.8 16.0 275 3.080 55 45 47
16 1.0 0.3 1.8 17.5 285 1.910 70 58 59
25 1.2 0.3 2.0 19.5 405 1.200 90 76 78
35 1.2 0.3 2.0 20.5 490 0.868 110 92 99
50 1.4 0.3 2.0 24.0 650 0.641 135 115 125
70 1.4 0.3 2.0 27.0 800 0.443 160 140 150
95 1.6 0.4 2.2 28.5 1065 0.320 190 170 185
120 1.6 0.4 2.2 33.0 1250 0.253 210 190 210
150 1.8 0.4 2.4 34.0 1550 0.206 240 210 240
185 2.0 0.5 2.4 37.0 1880 0.164 275 240 275
240 2.2 0.5 2.6 42.5 2400 0.125 320 275 325
300 2.4 0.6 2.8 45.5 2920 0.100 355 305 365
400 2.6 0.7 3.2 51.5 3815 0.078 385 345 420
500 3.0 0.7 3.4 57.0 4750 0.061 410 370 450
* If required, these sizes can be offered with stranded conductors also
9
8
 ©

Weight, Dimension data &

Current carrying capacity of
cables AN ISO 9001:2000
COMPANY

TABLE-7 “POLYCAB” KV TWIN CORE, COPPER CONDUCTOR, PVC INSULATED, INNER SHEATHED,
ARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE

Nominal Nominal Nomina Armour Minimu Approx Approx. Max. Dc Current Ratings
Cross Thickness l Galv. Galv. Flat m . Weight of Conductor Direct In Ducts In Air
Sectional of Thicknes Round Steel Strip Thicknes Overall Cable Resistanc In
Area Insulation s of Steel Nominal s of Diamete e at Ground
Inner Wire Thickness Outer r 20°C
Sheath Nominal Sheath
Dia.
Sq. mm mm mm mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps.
*1.5 0.8 0.3 1.4 - 1.24 12.5 350 12.100 23 20 20
*4.0 1.0 0.3 1.4 - 1.24 15.0 500 4.610 41 35 35
*2.5 0.9 0.3 1.4 - 1.24 13.5 415 7.410 32 27 27
*10 1.0 0.3 1.4 - 1.24 18.0 730 1.830 70 58 60
*6.0 1.0 0.3 1.4 - 1.24 16.0 580 3.080 50 44 45

16 1.0 0.3 - 0.8 1.40 18.0 740 1.150 90 75 78

25 1.2 0.3 - 0.8 1.40 20.0 960 0.727 115 97 105
35 1.2 0.3 - 0.8 1.40 21.5 1200 0.524 140 120 125
50 1.4 0.3 - 0.8 1.40 24.5 1580 0.387 165 145 155
70 1.4 0.3 - 0.8 1.56 28.0 2020 0.268 205 180 195
95 1.6 0.4 - 0.8 1.56 31.0 2650 0.193 240 215 230
120 1.6 0.4 - 0.8 1.56 33.0 3160 0.153 275 235 265
150 1.8 0.4 - 0.8 1.72 37.0 3870 0.124 310 270 305
185 2.0 0.5 - 0.8 1.88 40.5 4750 0.099 350 300 350
240 2.2 0.5 - 0.8 2.04 45.0 5930 0.075 405 345 410
300 2.4 0.6 - 0.8 2.20 56.0 7300 0.060 450 385 465
400 2.6 0.7 - 0.8 2.36 55.9 9450 0.047 490 425 530
* If required, these sizes can be offered with standard conductors also

TABLE-8 POLYCAB 1.1 KV TWIN CORE, COPPER CONDUCTOR, PVC INSULATED, INNER SHEATHED
UNARMOURED, PVC SHEATHED CABLES CONFORMING TO IS: 1554 (PART I) AMENDED UPTO DATE.
Nominal Nominal Nominal Nominal Approx Approx. Max. Dc Current Ratings
Cross Thickness of Thickness of Thickness . Weight Of Conductor Direct In Ducts In Air
Sectional Insulation Inner of Outer Overall Cable Resistance In
Area Sheath Sheath Diamete at 20°C Ground
r
Sq. mm mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps.
*1.5 0.8 0.3 1.8 11.0 135 12.100 23 20 20
*2.5
*4.0 0.9
1.0 0.3
0.3 1.8
1.8 12.0
13.5 185
235 7.410
4.610 32
41 27
35 27
35

*6.0
*10 1.0
1.0 0.3
0.3 1.8
1.8 14.5
16.0 295
400 3.080
1.830 50
70 44
58 45
60

16
25 1.0
1.2 0.3
0.3 1.8
2.0 17.5
19.5 485
715 1.150
0.727 90
115 75
97 78
105

35 1.2 0.3 2.0 20.5 925 0.524 140 120 125

70 1.4 0.3 2.0 27.0 1670 0.268 205 180 195

120 1.6 0.4 2.2 33.0 2750 0.153 275 235 265

185 2.0 0.5 2.4 37.0 4170 0.099 350 300 350

300 2.4 0.6 2.8 45.5 6640 0.060 450 385 465

9
 95 1.6 0.4 2.2 28.5 2250 0.193 240 215 230

150 1.8 0.4 2.4 34.0 3410 0.124 310 270 305

240 2.2 0.5 2.6 42.5 5370 0.075 405 345 410

400 2.6 0.7 3.2 51.5 8770 0.047 490 425 530
* If required, these sizes can be offered with stranded conductors also
 ©

Weight,Dimension
Weight, Dimensiondata
data&&
Current carrying capacity of cables
cables AN ISO 9001:2000
COMPANY

TABLE-9 “POLYCAB” 1.1 KV THREE CORE, ALUMINIUM CONDUCTOR, PVC INSULATED, INNER SHEATHED,
ARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE

Nominal Nominal Nomina Armour Minimu Approx Approx. Max. Dc Current Ratings
Cross Thickness l Galv. Galv. Flat m . Weight of Conductor Direct In Ducts In Air
Sectional of Thicknes Round Steel StripThicknes Overall Cable Resistanc In
Area Insulation s of Steel Nominal s of Diamete e at Ground
Inner Wire Thickness Outer r 20°C
Sheath Nominal Sheath
Dia.
Sq. mm mm mm mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps.
*1.5 0.8 0.3 1.4 - 1.24 12.5 375 18.100 16 14 13
*2.5 0.9 0.3 1.4 - 1.24 14.0 425 12.100 21 18 18
*4.0 1.0 0.3 1.4 - 1.24 15.5 500 7.410 28 23 23
*6.0 1.0 0.3 1.4 - 1.24 17.0 575 4.610 35 30 30
*10 1.0 0.3 1.4 - 1.4 19.0 700 3.080 46 39 40
16 1.0 0.3 - 0.8 1.40 20.0 650 1.910 60 50 51
25 1.2 0.3 - 0.8 1.40 22.0 800 1.200 76 63 70
35 1.2 0.3 - 0.8 1.40 25.0 950 0.868 92 77 86
50 1.4 0.3 - 0.8 1.56 27.0 1200 0.641 110 95 105
70 1.4 0.4 - 0.8 1.56 31.0 1500 0.443 135 115 130
95 1.6 0.4 - 0.8 1.56 34.0 1900 0.320 165 140 155
120 1.6 0.4 - 0.8 1.72 38.0 2240 0.253 185 155 180
150 1.8 0.5 - 0.8 1.88 42.0 2700 0.206 210 175 205
185 2.0 0.5 - 0.8 1.88 46.0 3200 0.164 235 200 240
240 2.2 0.6 - 0.8 2.20 52.0 3990 0.125 275 235 280
300 2.4 0.6 - 0.8 2.36 56.5 4850 0.100 305 260 315
400 2.6 0.7 - 0.8 2.52 64.0 6100 0.078 335 290 375
500 3.0 0.7 - 0.8 2.84 72.0 7600 0.061 350 310 410
* If required, these sizes can be offered with standard conductors also

TABLE-10 “POLYCAB” 1.1 KV THREE CORE, ALUMINIUM CONDUCTOR, PVC INSULATED, INNER SHEATHED
UNARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE

Nominal Nominal Nominal Nominal Approx Approx. Max. Dc Current Ratings

Cross Thickness of Thickness of Thickness . Weight Of Conductor Direct In Ducts In Air
Sectional Insulation Inner of Outer Overall Cable Resistance In
Area Sheath Sheath Diamete at 20°C Ground
r
Sq. mm mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps.
*1.5 0.8 0.3 1.8 11.5 130 18.100 16 14 13
*2.5 0.9 0.3 1.8 12.5 170 12.100 21 18 18
*4.0 1.0 0.3 1.8 13.5 210 7.410 28 23 23
*6.0 1.0 0.3 1.8 15.0 255 4.610 35 30 30
*10 1.0 0.3 1.8 16.5 325 3.080 46 39 40
16 1.0 0.3 1.8 17.5 360 1.910 60 50 51
25 1.2 0.3 2.0 22.0 520 1.200 76 63 70
35 1.2 0.3 2.0 23.0 640 0.868 92 77 86
50 1.4 0.3 2.0 27.0 850 0.641 110 95 105
70 1.4 0.4 2.2 31.0 1110 0.443 135 115 130
95 1.6 0.4 2.2 33.0 1425 0.320 165 140 155
120 1.6 0.4 2.2 36.0 1690 0.253 185 155 180
150 1.8 0.5 2.4 41.0 2120 0.206 210 175 205
185 2.0 0.5 2.6 45.0 2600 0.164 235 200 240
240 2.2 0.6 2.8 50.0 3290 0.125 275 235 280
300 2.4 0.6 3.0 55.5 4050 0.100 305 260 315
400 2.6 0.7 3.4 63.5 5290 0.078 335 290 375
500 3.0 0.7 3.8 71.0 6570 0.061 350 310 410
* If required, these sizes can be offered with stranded conductors also
1
10
 ©

Weight, Dimension data &

Current carrying capacity of
cables AN ISO 9001:2000
COMPANY

TABLE-11 “POLYCAB” 1.1 KV THREE CORE, COPPER CONDUCTOR, PVC INSULATED, INNER SHEATHED,
ARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE

Nominal Nomina Nomina Armour Minimu Approx Approx. Max. Dc Current Ratings
Cross l l Galv. Galv. Flat m . Weight of Conductor Direct In In Air
Sectional Thicknes Thicknes Round Steel Strip Thicknes Overall Cable Resistance In Ducts
Area s of s of Steel Nominal s Of Diamete at 20°C Ground
Insula- Inner Wire Thickness Outer r
tion Sheath Nominal Sheath
Dia.
Sq. mm mm mm mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps.
*1.5 0.8 0.3 1.4 - 1.24 12.5 405 12.100 21 17 17
*4.0 1.0 0.3 1.4 - 1.24 15.5 580 4.610 36 30 30
*2.5 0.9 0.3 1.4 - 1.24 14.0 475 7.410 27 24 24

*10 1.0 0.3 1.4 - 1.40 19.0 890 1.830 60 50 52

*6.0 1.0 0.3 1.4 - 1.24 17.0 700 3.080 45 38 39

16 1.0 0.3 - 0.8 1.40 20.0 950 1.150 77 64 66

25 1.2 0.3 - 0.8 1.40 22.0 1270 0.727 99 81 90
35 1.2 0.3 - 0.8 1.40 25.0 1600 0.524 120 99 110
50 1.4 0.3 - 0.8 1.56 27.0 2150 0.387 145 125 135
70 1.4 0.4 - 0.8 1.56 31.0 2800 0.268 175 150 165
95 1.6 0.4 - 0.8 1.56 34.0 3670 0.193 210 175 200
120 1.6 0.4 - 0.8 1.72 38.0 4470 0.153 240 195 230
150 1.8 0.5 - 0.8 1.88 42.0 5500 0.124 270 225 265
185 2.0 0.5 - 0.8 1.88 46.0 6650 0.099 300 255 305
240 2.2 0.6 - 0.8 2.2 52.0 8450 0.075 345 295 355
300 2.4 0.6 - 0.8 2.36 56.5 10450 0.060 385 335 400
400 2.6 0.7 - 0.8 2.52 64.0 13525 0.047 425 360 455
* If required, these sizes can be offered with standard conductors also

TABLE-12 “POLYCAB” 1.1 KV THREE CORE, COPPER CONDUCTOR, PVC INSULATED, INNER SHEATHED
UNARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE

Nominal Nominal Nominal Nominal Approx Approx. Max. Dc Current Ratings

Cross Thickness of Thickness of Thickness . Weight of Conductor Direct In Ducts In Air
Sectional Insulation Inner of Outer Overall Cable Resistance In
Area Sheath Sheath Diamete at 20°C Ground
r
Sq. mm mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps.
*1.5 0.8 0.3 1.8 11.5 160 12.100 21 17 17
*2.5
*4.0 0.9
1.0 0.3
0.3 1.8
1.8 12.5
13.5 220
290 7.410
4.610 27
36 24
30 24
30

*6.0
*10 1.0
1.0 0.3
0.3 1.8
1.8 15.0
16.5 370
510 3.080
1.830 45
60 38
50 39
52

16 1.0 0.3 1.8 17.5 660 1.150 77 64 66

35 1.2 0.3 2.0 23.0 1290 0.524 120 99 110

70 1.4 0.4 2.2 31.0 2410 0.268 175 150 165

120 1.6 0.4 2.2 36.0 3920 0.153 240 195 230

185 2.0 0.5 2.6 45.0 6040 0.099 300 255 305

300 2.4 0.6 3.0 55.5 9620 0.060 385 335 400

1
 95 1.6 0.4 2.2 33.0 3190 0.193 210 175 200

150 1.8 0.5 2.4 41.0 4910 0.124 270 225 265

240 2.2 0.6 2.8 50.0 7750 0.075 345 295 355

400 2.6 0.7 3.4 63.5 12715 0.047 425 360 455
* If required, these sizes can be offered with stranded conductors also
 ©

Weight,Dimension
Weight, Dimensiondata
data&&
Current carrying capacity of cables
cables AN ISO 9001:2000
COMPANY

TABLE-13 “POLYCAB” 1.1 KV 3 1/2 CORE, ALUMINIUM CONDUCTOR, PVC INSULATED, INNER SHEATHED,
ARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE

Nominal Nominal Minimu Armour Minimu Approx Approx Max. Dc Current Ratings
Cross Thickness of m Galv. m . . Conductor Direct In In In Air
Ssectional
Main Neutral Insulation
Main Neutral Thick- Flat Thick- Overall Weigh Resistance At
Main Neutral Ground Ducts
ness of Steel ness of Diamete t of
Inner Strip Outer r Cable
Sheath Nominal Sheath

Sq. mm Sq. mm mm mm mm Thicknes

mm mm mm Kgs./Km Ohm/Km Ohm/Km Amps. Amps. Amps.
25 16 1.2 1.0 0.3 0.8 1.40 23.5 900 1.200 1.910 76 63 70
35 16 1.2 1.0 0.3 0.8 1.40 26.0 1030 0.868 1.910 92 77 86
50 25 1.4 1.2 0.3 0.8 1.56 30.0 1350 0.641 1.200 100 95 105
70 35 1.4 1.2 0.4 0.8 1.56 32.5 1725 0.443 0.868 135 115 130
95 50 1.6 1.4 0.4 0.8 1.56 36.5 2130 0.320 0.641 165 140 155
120 70 1.6 1.4 0.5 0.8 1.72 40.5 2580 0.253 0.443 185 155 180
150 70 1.8 1.4 0.5 0.8 1.88 44.0 3050 0.206 0.443 210 175 205
185 95 2.0 1.6 0.5 0.8 2.04 50.0 3650 0.164 0.320 235 200 240
240 120 2.2 1.6 0.6 0.8 2.20 55.0 4580 0.125 0.253 275 235 280
300 150 2.4 1.8 0.6 0.8 2.36 61.0 5500 0.100 0.206 305 260 315
400 185 2.6 2.0 0.7 0.8 2.68 68.0 7000 0.078 0.164 335 290 375
500 240 3.0 2.2 0.7 0.8 2.84 75.0 8600 0.061 0.125 350 310 410

TABLE-14 “POLYCAB” 1.1 KV 3 1/2 CORE, ALUMINIUM CONDUCTOR, PVC INSULATED, INNER SHEATHED,
UNARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE

Nominal Nominal Thickness Minimu Nomina Approx Approx. Max. Dc Current Ratings
Cross of Insulation m l . Weight of Conductor
Sectional Thicknes Thicknes Overall Cable Resistance at
Area s of s of Diamete 20°C
Main Neutral Main Neutral Inner Outer r Main Neutral
Direct In Ducts In Air
Sheath Sheath In
Groun
d
Sq. mm Sq. mm Sq. mm Sq. mm mm mm mm Kgs./Km Ohm/Km Ohm/Km Amps. Amps. Amps.
25 16 1.2 1.0 0.3 2.0 22.5 615 1.200 1.910 76 63 70
35 16 1.2 1.0 0.3 2.0 25.0 715 0.868 1.910 92 77 86
50 25 1.4 1.2 0.3 2.2 29.0 955 0.641 1.200 110 95 105
70 35 1.4 1.2 0.4 2.2 33.0 1290 0.443 0.868 135 115 130
95 50 1.6 1.4 0.4 2.2 36.5 1640 0.320 0.641 165 140 155
120 70 1.6 1.4 0.5 2.4 39.0 2020 0.253 0.443 185 155 180
150 70 1.8 1.4 0.5 2.4 42.5 2380 0.206 0.443 210 175 205
185 95 2.0 1.6 0.5 2.6 47.0 2945 0.164 0.320 235 200 240
240 120 2.2 1.6 0.6 3.0 54.0 3800 0.125 0.253 275 235 280
300 150 2.4 1.8 0.6 3.2 58.0 4650 0.100 0.206 305 260 315
400 185 2.6 2.0 0.7 3.4 65.0 6000 0.078 0.164 335 290 375 1
 500 240 3.0 2.2 0.7 3.8 74.0 7400 0.061 0.125 350 310 410

12
 ©

Weight, Dimension data &

Current carrying capacity of
cables AN ISO 9001:2000
COMPANY

TABLE-15 “POLYCAB” 1.1 KV 3 1/2 CORE, COPPER CONDUCTOR, PVC INSULATED, INNER SHEATHED,
ARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE

Nominal Nominal Minimu Armour Minimu Approx Approx Max. Dc Current Ratings
Cross Thickness of m Galv. m . . Conductor Direct In In In Air
Ssectional
Main Neutral Insulation
Main Neutral Thick- Flat Thick- Overall Weigh Resistance At
Main Neutral Ground Ducts
ness of Steel ness of Diamete t of
Inner Strip Outer r Cable
Sheath Nominal Sheath

Sq. mm Sq. mm mm mm mm Thicknes

mm mm mm Kgs./Km Ohm/Km Ohm/Km Amps. Amps. Amps.
25 16 1.2 1.0 0.3 0.8 1.40 23.5 1465 0.727 1.150 99 81 90
35 16 1.2 1.0 0.3 0.8 1.40 26.0 1780 0.524 1.150 120 99 110
50 25 1.4 1.2 0.3 0.8 1.56 30.0 2435 0.387 0.727 145 125 135
70 35 1.4 1.2 0.4 0.8 1.56 32.5 3245 0.268 0.524 175 150 165
95 50 1.6 1.4 0.4 0.8 1.56 36.5 4210 0.193 0.387 210 175 200
120 70 1.6 1.4 0.5 0.8 1.72 40.5 5240 0.153 0.268 240 195 230
150 70 1.8 1.4 0.5 0.8 1.88 44.0 6270 0.124 0.268 270 225 265
185 95 2.0 1.6 0.5 0.8 2.04 50.0 7675 0.099 0.193 300 255 305
240 120 2.2 1.6 0.6 0.8 2.20 55.0 9780 0.075 0.153 345 295 355
300 150 2.4 1.8 0.6 0.8 2.36 61.0 12000 0.060 0.124 385 335 400
400 185 2.6 2.0 0.7 0.8 2.68 68.0 15570 0.047 0.099 425 360 455

TABLE-16 “POLYCAB” 1.1 KV 3 1/2 CORE, COPPER CONDUCTOR, PVC INSULATED, INNER SHEATHED,
UNARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE

Nominal Nominal Thickness Minimu Nomina Approx Approx. Max. Dc Current Ratings
Cross of Insulation m l . Weight of Conductor
Sectional Thicknes Thicknes Overall Cable Resistance at
Area s of s of Diamete 20°C
Main Neutral Main Neutral Inner Outer r Main Neutral
Direct In Ducts In Air
Sheath Sheath In
Groun
d
Sq. mm Sq. mm Sq. mm Sq. mm mm mm mm Kgs./Km Ohm/Km Ohm/Km Amps. Amps. Amps.
25 16 1.2 1.0 0.3 2.0 22.5 1180 0.727 1.150 99 81 90
35 16 1.2 1.0 0.3 2.0 25.0 1465 0.524 1.150 120 99 110
50 25 1.4 1.2 0.3 2.2 29.0 2040 0.387 0.727 145 125 135
70 35 1.4 1.2 0.4 2.2 33.0 2810 0.268 0.524 175 150 165
95 50 1.6 1.4 0.4 2.2 36.5 3715 0.193 0.387 210 175 200
120 70 1.6 1.4 0.5 2.4 39.0 4680 0.153 0.268 240 195 230
150 70 1.8 1.4 0.5 2.4 42.5 5600 0.124 0.268 270 225 265
185 95 2.0 1.6 0.5 2.6 47.0 6970 0.099 0.193 300 255 305
240 120 2.2 1.6 0.6 3.0 54.0 9000 0.075 0.153 345 295 355

1
300 150 2.4 1.8 0.6 3.2 58.0 11150 0.060 0.124 385 335 400
400 185 2.6 2.0 0.7 3.4 65.0 14570 0.047 0.099 425 360 455
 ©

Weight, Dimension data &

Current carrying capacity of cables
cables AN ISO 9001:2000
COMPANY

TABLE-17 “POLYCAB” 1.1 KV FOUR CORE, ALUMINIUM CONDUCTOR, PVC INSULATED, INNER SHEATHED,
ARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE
Nominal Nomina Nomina Armour Minimu Approx Approx. Max. Dc Current Ratings
Cross l l Galv. Galv. Flat m . Weight of Conductor Direct In In Air
Sectional Thicknes Thicknes Round Steel Strip Thicknes Overall Cable Resistance In Ducts
Area s of s of Steel Nominal s of Diamete at 20°C Groun
Insula- Inner Wire Thickness Outer r d
tion Sheath Nominal Sheath
Dia.
Sq. mm mm mm mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps.
*1.5 0.8 0.3 1.4 - 1.24 15.0 400 18.100 16 14 13
*2.5 0.9 0.3 1.4 - 1.24 16.5 480 12.100 21 18 18
*4.0 1.0 0.3 1.4 - 1.24 18.0 550 7.410 28 23 23
*6.0 1.0 0.3 1.4 - 1.24 19.5 650 4.610 35 30 30
*10 1.0 0.3 - 0.8 1.40 20.0 660 3.080 46 39 40
16 1.0 0.3 - 0.8 1.40 23.0 750 1.910 60 50 51
25 1.2 0.3 - 0.8 1.40 24.0 950 1.200 76 63 70
35 1.2 0.3 - 0.8 1.40 27.0 1165 0.868 92 77 86
50 1.4 0.4 - 0.8 1.56 31.0 1540 0.641 110 95 105
70 1.4 0.4 - 0.8 1.56 35.0 1800 0.443 135 115 130
95 1.6 0.4 - 0.8 1.72 38.0 2400 0.320 165 140 155
120 1.6 0.5 - 0.8 1.88 42.0 2800 0.253 185 155 180
150 1.8 0.5 - 0.8 1.88 46.0 3350 0.206 210 175 205
185 2.0 0.6 - 0.8 2.04 51.0 4000 0.164 235 200 240
240 2.2 0.6 - 0.8 2.36 58.0 5050 0.125 275 235 280
300 2.4 0.7 - 0.8 2.52 66.0 6200 0.100 305 260 315
400 2.6 0.7 - 0.8 2.84 72.0 7850 0.078 335 290 375
500 3.0 0.7 - 0.8 3.00 80.0 9600 0.061 350 310 410
* If required, these sizes can be offered with standard conductors also

TABLE-18 “POLYCAB” 1.1 KV FOUR CORE, ALUMINIUM CONDUCTOR, PVC INSULATED, INNER SHEATHED,
UNARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE
Nominal Nominal Nominal Nominal Approx Approx. Max. Dc Current Ratings
Cross Thickness of Thickness of Thickness . Weight Of Conductor Direct In In In Air
Sectional Insulation Inner of Outer Overall Cable Resistance Ground Ducts Amps
Area Sheath Sheath Diamete at 20°C Amps Amp
r s
Sq. mm mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps.
*1.5 0.8 0.3 1.8 12.5 150 18.100 16 14 13
*2.5 0.9 0.3 1.8 14.0 180 12.100 21 18 18
*4.0 1.0 0.3 1.8 15.5 220 7.410 28 23 23
*6.0 1.0 0.3 1.8 17.0 260 4.610 35 30 30
*10 1.0 0.3 1.8 19.0 340 3.080 46 39 40
16 1.0 0.3 2.0 21.5 460 1.910 60 50 51
25 1.2 0.3 2.0 24.0 600 1.200 76 63 70
35 1.2 0.3 2.0 26.5 800 0.868 92 77 86
50 1.4 0.4 2.2 32.5 1100 0.641 110 95 105
70 1.4 0.4 2.2 33.5 1400 0.443 135 115 130
95 1.6 0.4 2.4 38.5 1850 0.320 165 140 155
120 1.6 0.5 2.4 41.5 2250 0.253 185 155 180
150 1.8 0.5 2.6 46.0 2750 0.206 210 175 205
185 2.0 0.6 2.6 50.5 3400 0.164 235 200 240
240 2.2 0.6 3.0 58.0 4300 0.125 275 235 280
300 2.4 0.7 3.4 64.0 5300 0.100 305 260 315
400 2.6 0.7 3.6 72.0 6900 0.078 335 290 375
500 3.0 0.7 4.0 80.0 8600 0.061 350 310 410
1
 * If required, these sizes can be offered with stranded conductors also

14
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Weight, Dimension data &

Current carrying capacity of
cables AN ISO 9001:2000
COMPANY

TABLE-19 “POLYCAB” 1.1 KV FOUR CORE, COPPER CONDUCTOR, PVC INSULATED, INNER SHEATHED,
ARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE
Nominal Nomina Nomina Armour Minimu Approx Approx. Max. Dc Current Ratings
Cross l l Galv. Galv. Flat m . Weight of Conductor Direct In In Air
Sectional Thicknes Thicknes Round Steel Strip Thicknes Overall Cable Resistance In Ducts
Area s of s of Steel Nominal s of Diamete at 20°C Groun
Insula- Inner Wire Thickness Outer r d
tion Sheath Nominal Sheath
Dia.
Sq. mm mm mm mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps.
*1.5 0.8 0.3 1.4 - 1.24 15.0 440 12.100 21 17 17
*4.0 1.0 0.3 1.4 - 1.24 18.0 650 4.610 36 30 30
*2.5 0.9 0.3 1.4 - 1.24 16.5 550 7.410 27 24 24
*10 1.0 0.3 - 0.8 1.40 20.0 910 1.830 60 50 52
*6.0 1.0 0.3 1.4 - 1.24 19.5 800 3.080 45 38 39

16 1.0 0.3 - 0.8 1.40 23.0 1150 1.150 77 64 66

25 1.2 0.3 - 0.8 1.40 24.0 1570 0.727 99 81 90
35 1.2 0.3 - 0.8 1.40 27.0 2035 0.524 120 99 110
50 1.4 0.4 - 0.8 1.56 31.0 2780 0.387 145 125 135
70 1.4 0.4 - 0.8 1.56 35.0 3540 0.268 175 150 165
95 1.6 0.4 - 0.8 1.72 38.0 4760 0.193 210 175 200
120 1.6 0.5 - 0.8 1.88 42.0 5770 0.153 240 195 230
150 1.8 0.5 - 0.8 1.88 46.0 7065 0.124 270 225 265
185 2.0 0.6 - 0.8 2.04 51.0 8580 0.099 300 255 305
240 2.2 0.6 - 0.8 2.36 58.0 11000 0.075 345 295 355
300 2.4 0.7 - 0.8 2.52 66.0 13625 0.060 385 335 400
400 2.6 0.7 - 0.8 2.84 80.0 17750 0.047 425 360 455
* If required, these sizes can be offered with standard conductors also

TABLE-20 “POLYCAB” 1.1 KV FOUR CORE, COPPER CONDUCTOR, PVC INSULATED, INNER SHEATHED,
UNARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE

Nominal Nominal Nominal Nominal Approx Approx. Max. Dc Current Ratings

Cross Thickness of Thickness of Thickness . Weight of Conductor Direct In Ducts In Air
Sectional Insulation Inner of Outer Overall Cable Resistance In
Area Sheath Sheath Diamete at 20° C Groun
r d
Sq. mm mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps.
*1.5 0.8 0.3 1.8 12.5 190 12.100 21 17 17
*4.0
*2.5 1.0
0.9 0.3 1.8 15.5
14.0 320
245 4.610
7.410 36
27 30
24 30
24

*10
*6.0 1.0 0.3 1.8 19.0
17.0 590
410 1.830
3.080 60
45 50
38 52
39

16 1.0 0.3 2.0 21.5 860 1.150 77 64 66

35 1.2 0.3 2.0 26.5 1670 0.524 120 99 110

70 1.4 0.4 2.2 33.5 3140 0.268 175 150 165

120 1.6 0.5 2.4 41.5 5220 0.153 240 195 230

185 2.0 0.6 2.6 50.5 7980 0.099 300 255 305

300 2.4 0.7 3.4 64.0 12730 0.060 385 335 400

15
 95 1.6 0.4 2.4 38.5 4210 0.193 210 175 200

150 1.8 0.5 2.6 46.0 6470 0.124 270 225 265

240 2.2 0.6 3.0 58.0 10250 0.075 345 295 355

400 2.6 0.7 3.6 72.0 16800 0.047 425 360 455
* If required, these sizes can be offered with stranded conductors also
 ©

Weight,Dimension
Weight, Dimensiondata
data&&
Current carrying capacity of cables
cables AN ISO 9001:2000
COMPANY

TABLE-21 “POLYCAB” 1.1 KV, ANNEALED HIGH CONDUCTIVITY SOLID COPPER CONDUCTOR, 1.5 SQ.MM
PVC INSULATED, INNER SHEATHED, ARMOURED / UNARMOURED PVC SHEATHED
CONTROL CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE
Numbe Nomin Min. Armour Nomina Minimu Approx. Approx. Max. Dc Current Ratings
r of al Thick Galv. Galv. l m Overall Diameter Weight of Cable Conducto Direct In In
Cores Thicknes - Round Flat Sheath Sheath Unar- Ar- Unar- Ar- r In Duct Air
s of ness Steel Steel Thicknes Thicknes moured moured moured moured Resistanc Ground s
Insula- of Wire Strip s Unar- s e at
-tion Inner Nom. Nom. moured Armoure 20°C
mm mm mm mm mm mm mm mm Kgs./Km Kgs./Km Ohm/Km Amps. Amps. Amps.
2 0.8 0.3 1.4 - 1.80 1.24 10.50 13.50 130 350 12.1 23 20 20
3 0.8 0.3 1.4 - 1.80 1.24 11.00 14.00 160 400 12.1 21 17 17
4 0.8 0.3 1.4 - 1.80 1.24 11.50 15.00 190 450 12.1 21 17 17
5 0.8 0.3 1.4 - 1.80 1.24 12.50 15.50 225 500 12.1 21 17 17
6 0.8 0.3 1.4 - 1.80 1.24 13.00 16.00 250 550 12.1 15 13 13
7 0.8 0.3 1.4 - 1.80 1.24 13.50 16.50 265 565 12.1 14 13 13
10 0.8 0.3 1.4 - 1.80 1.40 16.50 19.00 350 750 12.1 13 11 11
12 0.8 0.3 - 0.8 1.80 1.24 17.50 19.50 400 650 12.1 12 10 10
14 0.8 0.3 - 0.8 1.80 1.40 18.00 20.00 450 760 12.1 11 10 10
16 0.8 0.3 - 0.8 1.80 1.40 19.50 21.00 500 800 12.1 11 9 9
19 0.8 0.3 - 0.8 2.00 1.40 20.00 22.00 600 850 12.1 10 9 9
24 0.8 0.3 - 0.8 2.00 1.40 23.00 25.00 725 1050 12.1 9 8 8
30 0.8 0.3 - 0.8 2.00 1.40 24.50 26.50 860 1200 12.1 9 7 7
37 0.8 0.3 - 0.8 2.00 1.40 26.00 28.00 1050 1400 12.1 8 7 7
61 0.8 0.4 - 0.8 2.20 1.56 33.00 35.00 1650 2100 12.1 7 6 6

TABLE-22 “POLYCAB” 1.1 KV, ANNEALED HIGH CONDUCTIVITY SOLID COPPER CONDUCTOR, 2.5 SQ.MM
PVC INSULATED, INNER SHEATHED, ARMOURED / UNARMOURED PVC SHEATHED
CONTROL CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE
Numbe Nomin Min. Armour Nomina Minimu Approx. Approx. Max. Dc Current Ratings
r of al Thick Galv. Galv. l m Overall Weight of Conducto Direct In In
Cores Thicknes - Round Flat Sheath Sheath Unar-DiameterAr- Cable Ar-
Unar- r In Duct Air
s of ness Steel Steel Thicknes Thicknes moured moured moured moured Resistanc Ground s
Insula- of Wire Strip s Unar- s e At
-tion Inner Nom. moured Armoure 20°C
mm mm mm Nom. mm mm mm mm mm Kgs./Km Kgs./Km Ohm/Km Amps. Amps. Amps.
2 0.9 0.3 1.4 - 1.8 1.24 11.00 14.50 160 425 7.41 32 27 27
3 0.9 0.3 1.4 - 1.8 1.24 11.50 15.50 225 475 7.41 27 24 24
4 0.9 0.3 1.4 - 1.8 1.24 11.50 16.50 250 530 7.41 27 24 24
5 0.9 0.3 1.4 - 1.8 1.24 14.00 17.50 300 600 7.41 27 24 24
6 0.9 0.3 1.4 - 1.8 1.24 15.50 18.50 340 675 7.41 20 18 18
7 0.9 0.3 1.4 - 1.8 1.24 15.50 18.50 375 700 7.41 20 17 17
10 0.9 0.3 - 0.8 1.8 1.40 19.00 21.00 500 780 7.41 18 15 15
12 0.9 0.3 - 0.8 2.0 1.40 20.00 22.00 600 850 7.41 17 14 14
14 0.9 0.3 - 0.8 2.0 1.40 21.00 23.00 650 950 7.41 16 13 13
16 0.9 0.3 - 0.8 2.0 1.40 22.00 24.00 750 1050 7.41 15 13 13
19 0.9 0.3 - 0.8 2.0 1.40 23.00 25.00 850 1150 7.41 14 12 12
24 0.9 0.3 - 0.8 2.0 1.40 27.00 29.00 1050 1400 7.41 13 11 11
30 0.9 0.3 - 0.8 2.0 1.56 28.50 30.50 1250 1700 7.41 12 10 10
37 0.9 0.4 - 0.8 2.2 1.56 31.00 33.00 1550 2000 7.41 11 10 10
61 0.9 0.4 - 0.8 2.2 1.56 38.50 41.00 2450 3100 7.41 9 8 8

16 17
 ©

Weight, Dimension data &

Current carrying capacity of
cables AN ISO 9001:2000
COMPANY

TABLE-23 CONDUCTOR RESISTANCE OF PLAIN COPPER CONDUCTORS

USED FOR HEAVY DUTY CABLES AS PER IS : 8130-1984

Size in sq.mm Conduct Max.cond. Size in sq.mm Conduct Max. cond.

or resistance in or resistance in
Constructio Ohm/Km at Constructio Ohm/Km at
n 20°C Single n 20°C Single
Core & Multi Core & Multi
Core Core
1.5* 1/1.38 12.100 120 37/2.03 0.153
2.5* 1/1.78 7.410 150 37/2.24 0.124
4.0* 1/2.24 4.610 185 37/2.50 0.099
6.0* 1/2.76 3.080 240 61/2.24 0.075
10.0 7/1.35 1.830 300 61/2.50 0.060
16.0 7/1.70 1.150 400 61/2.85 0.047
25.0 7/2.14 0.727 500 61/3.20 0.037
35.0 7/2.50 0.524 630 91/3.00 0.028
50.0 7/3.00 0.387 - - -
70.0 19/2.14 0.268 800 127/2.83 0.022
95.0 19/2.50 0.193 1000 127/3.16 0.018

TABLE-24 CURRENT RATING OF ‘“POLYCAB” COPPER ARMOURED / UNARMOURED CABLES

650 / 1100 V GRADE IN AIR.

Area Twin Core 3, 3 1/2, 4 Core Area Twin Core 3, 3 1/2, 4 Core

sq.mm Amp. Amp. sq.mm Amp. Amp.

1.5 20 17 70 195 165
2.5 27 24 95 230 200
4.0 35 30 120 265 235
6.0 45 39 150 305 265
10.0 60 52 185 350 305
16.0 78 66 240 410 355
25.0 105 90 300 465 400
35.0 125 110 400 530 455
50.0 155 135 - - -

17
Weight, Dimension data &
Current carrying capacity of cables

TABLE-25 ESTIMATED A.C RESISTANCE, REACTANCE, CAPACITANCE, IMPEDANCE, VOLTAGE

DROP AND SHORTCIRCUIT RATING FOR PVC INSULATED, ALUMINIUM CONDUCTOR,
ARMOURED SINGLE CORE CABLES.

Nominal area of A.C Resistance Reactance at 50 Hz Capacitance Impedance at 70°C Voltage Drop Short circuit ratings of
Conductor at 70°C conductor for 1 second
thickness of
Outersheath
mm² Ohm/Km Ohm/Km µF/Km Ohm/Km V/Km/A kA
16 2.3000 0.1250 0.81 2.3000 3.980 1.22
25 1.4400 0.1200 0.83 1.4500 2.510 1.90
35 1.0400 0.1140 0.95 1.0500 1.820 2.66
50 0.7700 0.1120 0.95 0.7780 1.350 3.80
70 0.5330 0.1040 1.13 0.5430 0.940 5.32
95 0.3850 0.0970 1.17 0.3970 0.688 7.22
120 0.3050 0.0926 1.32 0.3180 0.552 9.12
150 0.2480 0.0916 1.30 0.2650 0.459 11.41
185 0.1980 0.0895 1.35 0.2170 0.377 14.07
240 0.1520 0.0876 1.40 0.1750 0.303 18.25
300 0.1220 0.0863 1.44 0.1500 0.259 22.81
400 0.0961 0.0845 1.48 0.1280 0.222 30.41
500 0.0761 0.0835 1.47 0.1130 0.196 38.02
630 0.0606 0.0833 1.45 0.1030 0.178 47.90
800 0.0495 0.0816 1.61 0.0954 0.165 60.83
1000 0.0416 0.0797 1.81 0.0899 0.156 76.03

TABLE-26 ESTIMATED A.C RESISTANCE, REACTANCE, CAPACITANCE, IMPEDANCE, VOLTAGE

DROP AND SHORT CIRCUIT RATING FOR PVC INSULATED,
ALUMINIUM CONDUCTOR, ARMOURED MULTI CORE CABLES.
Nominal area of A.C Resistance Reactance at 50 Hz Capacitance Impedance at 70°C Voltage Drop Short circuit ratings of
Conductor at 70°C conductor for 1
second thickness of
Outersheath
mm² Ohm/Km Ohm/Km µF/Km ohm/Km V/Km/A kA
1.5 21.7000 0.1120 0.38 21.700 37.700 0.11
2.5 14.5000 0.1100 0.41 14.500 25.200 0.19
4.0 8.9000 0.1050 0.45 8.900 15.400 0.30
6.0 5.5400 0.0988 0.52 5.540 9.600 0.46
10.0 3.7000 0.0938 0.60 3.700 6.410 0.76
16.0 2.3000 0.0862 0.80 2.300 3.980 1.22
25.0 1.4400 0.0854 0.84 1.440 2.500 1.90
35.0 1.0400 0.0827 0.96 1.050 1.810 2.66
50.0 0.7700 0.0825 0.98 0.775 1.340 3.80
70.0 0.5330 0.0771 1.12 0.538 0.932 5.32
95.0 0.3850 0.0767 1.16 0.393 0.680 7.22
120.0 0.3050 0.0744 1.28 0.314 0.543 9.12
150.0 0.2490 0.0745 1.26 0.259 0.449 11.41
185.0 0.1980 0.0744 1.28 0.212 0.367 14.07
240.0 0.1520 0.0740 1.31 0.169 0.293 18.25
300.0 0.1220 0.0732 1.35 0.142 0.247 22.81
400.0 0.0961 0.0727 1.40 0.121 0.209 30.41

18
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Weight, Dimension data &

Current carrying capacity of
cables AN ISO 9001:2000
COMPANY

TABLE-27 ESTIMATED A.C RESISTANCE, REACTANCE, CAPACITANCE, IMPEDANCE, VOLTAGE DROP AND SHORT
CIRCUIT RATING FOR HR PVC INSULATED, ALUMINIUM CONDUCTOR,
ARMOURED SINGLE CORE CABLES.

Nominal area of A.C Resistance Reactance at 50 Hz Capacitance Impedance at 85°C Voltage Drop Short circuit
Conductor at 85°C ratings of
conductor for 1
second thickness
of Outersheath
mm² Ohm/Km Ohm/Km µF/Km Ohm/Km V/Km/A kA
16 2.4100 0.1250 0.81 2.4100 4.180 1.01
25 1.5100 0.1200 0.83 1.5200 2.630 1.72
35 1.0100 0.1140 0.95 1.1000 1.910 2.40
50 0.8090 0.1120 0.95 0.8170 1.410 3.43
70 0.5590 0.1040 1.13 0.5690 0.985 4.80
95 0.4040 0.0970 1.17 0.4160 0.720 6.52
120 0.3200 0.0926 1.32 0.3330 0.577 8.23
150 0.2610 0.0916 1.30 0.2760 0.479 10.29
185 0.2080 0.0895 1.35 0.2260 0.392 12.69
240 0.1590 0.0876 1.40 0.1820 0.315 16.46
300 0.1280 0.0863 1.44 0.1540 0.267 20.58
400 0.1010 0.0845 1.48 0.1310 0.228 27.44
500 0.0796 0.0835 1.47 0.1150 0.200 34.30
630 0.0632 0.0833 1.45 0.1050 0.181 43.21
800 0.0515 0.0816 1.61 0.0964 0.167 54.88
1000 0.0431 0.0797 1.81 0.0906 0.157 68.59

TABLE-28 ESTIMATED A.C RESISTANCE, REACTANCE, CAPACITANCE, IMPEDANCE, VOLTAGE

DROP AND SHORT CIRCUIT RATING FOR HR PVC INSULATED, ALUMINIUM CONDUCTOR,
ARMOURED MULTI CORE CABLES.
Nominal area of A.C Resistance Reactance at 50 Hz Capacitance Impedance at 85°C Voltage Drop Short circuit
Conductor at 85°C ratings of
conductor for 1
second thickness
of Outersheath
mm² Ohm/Km Ohm/Km µF/Km Ohm/Km V/Km/A kA
1.5 22.800 0.1120 0.38 22.800 39.600 0.10
2.5 15.300 0.1100 0.41 15.300 26.400 0.17
4.0 9.350 0.1050 0.45 9.350 16.200 0.27

6.0 5.820 0.0988 0.52 5.820 10.100 0.41

10.0 3.890 0.0938 0.60 3.890 6.730 0.69
16.0 2.410 0.0862 0.80 2.410 4.180 1.01
25.0 1.510 0.0854 0.84 1.520 2.630 1.72
35.0 1.010 0.0827 0.96 1.010 1.900 2.40
50.0 0.809 0.0825 0.98 0.813 1.41 3.43
70.0 0.559 0.0771 1.12 0.565 0.978 4.80
95.0 0.404 0.0767 1.16 0.412 0.713 6.52
120.0 0.320 0.0744 1.28 0.329 0.569 8.23
150.0 0.261 0.0745 1.26 0.271 0.470 10.29
185.0 0.208 0.0744 1.28 0.221 0.383 12.69
240.0 0.159 0.0740 1.31 0.176 0.304 16.46
300.0 0.128 0.0732 1.35 0.148 0.256 20.58
400.0 0.101 0.0727 1.40 0.124 0.215 27.44

19
Weight, Dimension data &
Current carrying capacity of cables

TABLE-29 ESTIMATED A.C RESISTANCE, REACTANCE, CAPACITANCE, IMPEDANCE, VOLTAGE

DROP AND SHORT CIRCUIT RATING FOR PVC INSULATED, COPPER CONDUCTOR,
ARMOURED SINGLE CORE CABLES.

Nominal area A.C Resistance Reactance at 50 Hz Capacitance Impedance at 70°C Voltage Drop Short circuit rat-
of at 70°C ings of
Conductor conductor for 1
second
thickness of
Outersheath
mm² Ohm/Km Ohm/Km µF/Km Ohm/Km V/Km/A kA
16 1.3800 0.1250 0.81 1.3800 2.390 1.84
25 0.8700 0.1200 0.83 0.8780 1.520 2.88
35 0.6270 0.1140 0.95 0.6380 1.100 4.03
50 0.4630 0.1120 0.95 0.4770 0.830 5.75
70 0.3210 0.1040 1.13 0.3370 0.585 8.05
95 0.2320 0.0970 1.17 0.2510 0.435 10.93
120 0.1840 0.0926 1.32 0.2060 0.357 13.80
150 0.1500 0.0916 1.30 0.1760 0.304 17.25
185 0.1200 0.0895 1.35 0.1500 0.260 21.28
240 0.0928 0.0876 1.40 0.1280 0.221 27.60
300 0.0751 0.0863 1.44 0.1140 0.198 34.50
400 0.0604 0.0845 1.48 0.1040 0.180 46.00
500 0.0490 0.0835 1.47 0.0968 0.168 57.50
630 0.0401 0.0833 1.45 0.0925 0.160 72.45
800 0.0339 0.0816 1.61 0.0883 0.153 92.00
1000 0.0297 0.0797 1.81 0.0850 0.147 115.00

TABLE-30 ESTIMATED A.C RESISTANCE, REACTANCE, CAPACITANCE, IMPEDANCE, VOLTAGE

DROP AND SHORT CIRCUIT RATING FOR PVC INSULATED, COPPER CONDUCTOR,
ARMOURED MULTI CORE CABLES.
Nominal area of A.C Resistance Reactance at 50 Hz Capacitance Impedance at 70°C Voltage Drop Short circuit rat-
Conductor at 70°C ings of conduc-
tor for 1 second
thickness of
Outersheath
mm² Ohm/Km Ohm/Km µF/Km Ohm/Km V/Km/A kA
1.5 14.5000 0.1140 0.37 14.500 25.100 0.17
2.5 8.9000 0.1100 0.40 8.900 15.400 0.29
4.0 5.5200 0.1060 0.44 5.520 9.560 0.46
6.0 3.6900 0.1001 0.51 3.690 6.390 0.69
10.0 2.1900 0.0907 0.67 2.190 3.800 1.15
16.0 1.3800 0.0862 0.80 1.380 2.390 1.84
25.0 0.8700 0.0854 0.84 0.870 1.510 2.88
35.0 0.6300 0.0827 0.96 0.630 1.010 4.03
50.0 0.4640 0.0825 0.98 0.471 0.815 5.75
70.0 0.3210 0.0771 1.12 0.331 0.572 8.05
95.0 0.2320 0.0767 1.16 0.244 0.423 10.93
120.0 0.1840 0.0744 1.28 0.199 0.344 13.80
150.0 0.1500 0.0745 1.26 0.168 0.290 17.25
185.0 0.1210 0.0744 1.28 0.142 0.246 21.28
240.0 0.0930 0.0740 1.31 0.119 0.206 27.60
300.0 0.0750 0.0732 1.35 0.105 0.182 34.50
400.0 0.0604 0.0727 1.40 0.095 0.164 46.00

20
 ©

Weight, Dimension data &

Current carrying capacity of
cables AN ISO 9001:2000
COMPANY

TABLE-31 ESTIMATED A.C RESISTANCE, REACTANCE, CAPACITANCE, IMPEDANCE, VOLTAGE DROP AND SHORT
CIRCUIT RATING FOR HR PVC INSULATED, COPPER CONDUCTOR,
ARMOURED SINGLE CORE CABLES.
Nominal area A.C Resistance Reactance at 50 Hz Capacitance Impedance at 85°C Voltage Drop Short circuit
of at 85°C ratings of
Conductor conductor for 1
second thickness
of Outersheath
mm² Ohm/Km Ohm/Km µF/Km Ohm/Km V/Km/A kA
16 1.4400 0.1250 0.81 1.4500 2.510 1.66
25 0.9130 0.1200 0.83 0.9210 1.590 2.59
35 0.6580 0.1140 0.95 0.6680 1.160 3.63
50 0.4860 0.1120 0.95 0.4990 0.864 5.19
70 0.3370 0.1040 1.13 0.3530 0.611 7.26
95 0.2430 0.0970 1.17 0.2620 0.453 9.86
120 0.1930 0.0926 1.32 0.2140 0.371 12.45
150 0.1570 0.0916 1.30 0.1820 0.315 15.57
185 0.1260 0.0895 1.35 0.1550 0.268 19.20
240 0.0971 0.0876 1.40 0.1310 0.226 24.91
300 0.0785 0.0863 1.44 0.1170 0.202 31.13
400 0.0630 0.0845 1.48 0.1050 0.183 41.51
500 0.0509 0.0835 1.47 0.0978 0.169 51.89
630 0.0416 0.0833 1.45 0.0931 0.161 65.38
800 0.0351 0.0816 1.61 0.0888 0.154 83.02
1000 0.0306 0.0797 1.81 0.0853 0.148 103.78

TABLE-32 ESTIMATED A.C RESISTANCE, REACTANCE, CAPACITANCE, IMPEDANCE, VOLTAGE DROP AND SHORT
CIRCUIT RATING FOR HR PVC INSULATED, COPPER CONDUCTOR,
ARMOURED MULTI CORE CABLES.
Nominal area of A.C Resistance Reactance at 50 Hz Capacitance Impedance at 85°C Voltage Drop Short circuit
Conductor at 85°C ratings of
conductor for 1
second thickness
of Outersheath
mm² Ohm/Km Ohm/Km µF/Km Ohm/Km V/Km/A kA
1.5 15.2000 0.1140 0.37 15.2000 26.300 0.16
2.5 9.3000 0.1100 0.40 9.3000 16.100 0.26
4.0 5.7900 0.1060 0.44 5.7900 10.000 0.42
6.0 3.8700 0.1001 0.51 3.8700 6.700 0.62
10.0 2.3000 0.0907 0.67 2.3000 3.980 1.04
16.0 1.4400 0.0862 0.80 1.4500 2.510 1.66
25.0 0.9130 0.0854 0.84 0.9170 1.590 2.59
35.0 0.6580 0.0827 0.96 0.6630 1.150 3.63
50.0 0.4860 0.0825 0.98 0.4930 0.854 5.19
70.0 0.3370 0.0771 1.12 0.3460 0.599 7.26
95.0 0.2430 0.0767 1.16 0.2550 0.442 9.86
120.0 0.1930 0.0744 1.28 0.2070 0.359 12.45
150.0 0.1570 0.0745 1.26 0.1740 0.301 15.57
185.0 0.1260 0.0744 1.28 0.1470 0.254 19.20
2400. 0.0972 0.0740 1.31 0.1220 0.212 24.91
300.0 0.0787 0.0732 1.35 0.1070 0.186 31.13
400.0 0.0630 0.0727 1.40 0.0962 0.167 41.51

21
Rating Factors

1) FOR AIR AND GROUND TEMPERATURE

A. Rating factors for variation in ambient air temperature
Ambient Temp (°C) 25 30 35 40 45 50
Rating Factors 1.25 1.16 1.09 1.00 0.90 0.80
B. Rating factors for variation in ground temperature
Ground Temp (°C) 15 20 25 30 35 40 45
Rating Factors 1.17 1.12 1.06 1.00 0.9 0.87 0.79
4
C. Rating factors for variation in ground temperature (for Cables in Ducts)
Ground Temp (°C) 15 20 25 30 35 40 45
Rating Factors 1.17 1.12 1.06 1.00 0.94 0.87 0.79

2) FOR DEPTH OF LAYING ( CABLES LAID DIRECT IN THE GROUND).

Depth of laying Size
Cm Upto 25 mm2 Above 25 mm2 Upto 300 mm2 Above 300 mm2
75 1.00 1.00 1.00
90 0.99 0.98 0.97
105 0.98 0.97 0.96
120 0.97 0.96 0.95
150 0.96 0.94 0.92
180 or more 0.95 0.93 0.91

3) FOR VARIATION IN THERMAL RESISTIVITY OF SOIL

(TWO AND THREE AND MULTICORE CABLES LAID DIRECT IN THE GROUND).
Nominal area Two cables touching for values of Thermal Resistivity of soil in °C cm / W
of conductor 100 120 150 200 250 300
mm2
1.5 1.10 1.05 1.00 0.92 0.86 0.81
2.5 1.10 1.05 1.00 0.92 0.86 0.81
4.0 1.10 1.05 1.00 0.92 0.86 0.81
6.0 1.10 1.05 1.00 0.92 0.86 0.81
10.0 1.10 1.06 1.00 0.92 0.85 0.80
16.0 1.12 1.06 1.00 0.91 0.84 0.79
25.0 1.14 1.08 1.00 0.91 0.84 0.78
35.0 1.15 1.08 1.00 0.91 0.84 0.77
50.0 1.15 1.08 1.00 0.91 0.84 0.77
70.0 1.15 1.08 1.00 0.90 0.83 0.76
95.0 1.15 1.08 1.00 0.90 0.83 0.76
120.0 1.17 1.09 1.00 0.90 0.82 0.76
150.0 1.17 1.09 1.00 0.90 0.82 0.75
185.0 1.18 1.09 1.00 0.89 0.81 0.75
240.0 1.18 1.09 1.00 0.89 0.81 0.75
300.0 1.18 1.09 1.00 0.89 0.81 0.75
400.0 1.19 1.10 1.00 0.89 0.81 0.75
 ©

Weight,
22 Dimension data &
Current carrying capacity of
cables AN ISO 9001:2000
COMPANY

23
 ©

Group Rating Factors

AN ISO 9001:2000 COMPANY

FOR SINGLE CORE CABLES

A) Cables laid direct in the ground in horizontal formation.
Distance between Trefoils
No. of Trefoils in Group
Touching 15 cm 30 cm 45 cm
2 0.78 0.81 0.85 0.88

3 0.68 0.71 0.77 0.81

4 0.61 0.65 0.72 0.76

5 0.56 0.61 0.68 0.73

B) Cables laid in ducts in horizontal formation.

Distance between Trefoils
No. of Trefoils in Group
Touching 45 cm 60 cm

2 0.87 0.90 0.91

3 0.79 0.83 0.86

4 0.74 0.79 0.82

5 0.71 0.76 0.80

C) Cables laid on racks / Trays in covered trench with having restricted air circulation, Trefoils are separated by
two cable diameter horizontally and the trays are in tiers having 30 cm distance.
No. of Trefoils in Horizontal Formation
No. racks / trays in tiers
1 2 3
1 0.95 0.90 0.88

2 0.90 0.85 0.83

3 0.88 0.83 0.81

6 0.86 0.81 0.79

D) as above C. but cables laid in open air.

No. of Trefoils in Horizontal Formation
No. racks / trays in tiers
1 2 3
1 1 0.98 0.96

2 1 0.95 0.93

3 1 0.94 0.92

6 1 0.93 0.90

23
 Group Rating Factors

FOR MULTI CORE CABLES

A) Cables laid on cable trays exposed to air, the cables spaced by one cable diameter and trays are in
tiers spaced by 30 cm. The clearance between the wall and the cable is 25 mm.
No. of cables trays in No. of Cables per Tray
tier 1 2 3 6 9
1 1 0.98 0.96 0.93 0.92
2 1 0.95 0.93 0.90 0.89
3 1 0.94 0.92 0.89 0.88
6 1 0.93 0.90 0.87 0.86

B) Cables laid inside concrete trench with removable covers on cable trays having restricted circulation. The
cables spaced by one cable diameter and trays are in tiers spaced by 30 cm. The clearance of the
cable from the wall is 25 mm.
No. of cables trays in No. of Cables per Tray
tier 1 2 3 6 9
1 0.95 0.90 0.88 0.85 0.84
2 0.90 0.85 0.83 0.81 0.80
3 0.88 0.83 0.81 0.79 0.78
6 0.86 0.81 0.79 0.77 0.76

C) Cables laid on cable trays exposed to air, the cable touching and trays are in tiers spaced by 30 cm.
The clearance between the wall and the cable is 25 mm.
No. of cables trays in No. of Cables per Tray
tier 1 2 3 6 9
1 1 0.84 0.80 0.75 0.73
2 1 0.80 0.76 0.71 0.69
3 1 0.78 0.74 0.70 0.68
6 1 0.76 0.72 0.68 0.66

D) Cables laid direct in ground in horizontal formation.

Distance of Cables
No. of cables in
Group Touching 15 cm 30 cm 45 cm
2 0.79 0.82 0.87 0.90
3 0.69 0.75 0.79 0.83
4 0.62 0.69 0.74 0.79
5 0.58 0.65 0.72 0.76
6 0.54 0.61 0.69 0.75

E) Cables laid in single way ducts / pipes in horizontal formation.

Distance of Cables
No. of cables in
Group Touching 30 cm 45 cm 60 cm
2 0.88 0.90 0.92 0.94
3 0.82 0.84 0.87 0.89
4 0.77 0.80 0.84 0.87
5 0.74 0.78 0.82 0.85
6 0.71 0.76 0.81 0.84

24
 ©

Selection of Cables
AN ISO 9001:2000 COMPANY

Power Cables are generally selected considering the application.

However, following factors are important for selection of suitable cable
construction required to transport electrical energy from one end to the
other.
1) Maximum operating voltage,
2) Fault Level,
3) Load to be carried,
4) Possible overloading duration & magnitude,
5) Route length and voltage drop.
6) Mode of installation considering install-lation environment such as ambient
& ground temperature chemical & physical properties of soil.
7) Flame retardant properties.
All sizes of POLYCAB PVC cables are designed to standard operating conditions
in India and abroad. The standards adopted are considering the geographical/
climatical conditions and general applications of power for utilities, distribution
and generation purposes.
The cables are manufactured conforming to Indian & International cables
specifications for PVC Insulated cables. Customer specific requirements can
also be met.

Flame Retardant Low Smoke Cables

The behaviour of Electric Cables in presence of fire has been a matter of great
concern to all Electrical Engineers involved in Generation, Transmission and
Utilisation of electric power. Normally all XLPE / PVC Cables have an outer sheath
of PVC. Although PVC by itself is flame retarding, it does produce highly toxic
and corrosive fumes in the event of fire.
As a matter of fact, in closed and crowded places such as power
stations, subways, railways with long sections in tunnels, road tunnels,
ships, hospitals, schools, hotels, cinema theatres, museums and public
premises in general, besides the obvious danger represented by fire
propagation, also fume toxicity and opacity are particularly important as they
may cause, with equally serious consequences for human safety,
suffocation intoxication and panic due to reduced visibility.
FRLS PVC compound should ensure the following :
1) Minimum smoke emission.
2) Very low toxic and corrosive fumes emission.
3) Fire Retardant characteristics.
Our laboratory is well equipped with latest test equipments to carry out
following test requirements.
a) The oxygen index and temperature index of sheath as per ASTM-D 2863.
b) Flammability characteristics of cable as per IEC-332 ( Pt. I ) & IEC-332 ( Pt. III )
c) Flammability characteristics of cables as per Swedish Standard SS 424 14 75,
Class F3.
25
d) Determination of the amount of halogen acid gas evolved during
combustion of outersheath materials as per per IEC 754 ( Pt. I ).
e) Determination of smoke generation of outersheath material under fire as per ASTM-D
2843
f) The measurement of smoke density as per IEC 61034.
‘Polycab’ Overload & Short Circuit Ratings

Normal current rating of POLYCAB cable as given in the tables takes into account
temporary
overloadingwhichoftenoccursinuse.However,tosafeguardagainstexcessivethermalda
mage, it is essential that protective switchgear of a proper rating is used
in circuit.
Cables laid in air or in ducts can safely be overloaded to 1.5 times the amount
given in the current rating tables for four hours provided the protective system
uses a class P fuse designed to operate at a 50% overload.
In case the protective circuit has a different fuse rating, select a cable by
multiplying the tripping current by 0.67 to arrive at a suitable size of
cable. For example, for carrying 200 amps current in the air 70 sq.mm.
single core cable is suitable (current rating is 230 amps.) This cable can
therefore be overloaded to the extent of 230 x
1.5 = 345 amp. provided that the protective fuse rating is 230 x 1.5 = 345.
However, if the protective fuse rating is 400 amps. normal rating 400 x
.67 = 268 amps., 95 sq. mm cable should be used. Similarly current
rating for cables in the ground can safely used for an overload factor of
1.3 for four hours. It is essential that the protection is designed to
operate at a 30% overload. In case this is different, select a cable to
carry 0.77 times the current at which protection is designed to operate.

SHORT CIRCUIT RATING FOR ALUMINIUM CONDUCTOR CABLES

With a high increase in KVA capacity of the power distribution system, cable are
expected to carry short circuit currents of high magnitude. Normally rated at
70° C, our insulating materials permit a short circuit temperature of 160° C.
With the high interrupting capacity expected of a cable under short circuit, it
is essential that protective fuses in the system are designed to minimise the
duration as far as possible. Short circuit rating of a cable can be calculated
as under

Where lsh = 75.8 x A lsh : Short circuit current in r. m. s. amps.

 t t : Duration of short circuit in seconds.
A : Area of conductor in sq.
mm Constants are tabulated below for different duration of
short circuit.
10 25 50
Duration cycle cycle cycle
cycle cycle cycle 2 3 4 5
of short=0.02 =0.04 =0.01
=0.02 =0.02 =0.02 seconds seconds seconds seconds
circuit inseconds seconds seconds
seconds seconds seconds
seconds
Short
circuits 536 378 239 169 107 75.7 53.0 43.6 37.8 34.0
constant
per unit area

Example : Short circuit rating of 150 sq.mm. conductor area with a short circuit duration of
0.5 seconds = 150 x 107 = 16050 amps.

SHORT CIRCUIT RATING FOR COPPER CONDUCTOR CABLES

The following formula gives the Short Circuit Rating of Copper conductor, PVC
insulated cables
27
Where lsh =
113 x A lsh : Short circuit current in r. m. s.
amps.
 t t : Duration of short circuit in
A : seconds.

26
 ©

Handling, Storage and Laying of Polycab Cables

AN ISO 9001:2000 COMPANY

A. CABLE INSPECTION B. CABLE HANDLING & STORAGE

Inspect every cable reel for damage Damage to cables can occur due
before accepting the shipment.Be to the incorrect handling to which
particularly alert for cable damage the drums and cables may be
if: subjected; causing breakdown of
1. A reel is lying flat on its side the drum flanges and in
exceptional cases, movement of the
2. Several reels are stacked drum barrel takes place. Once this
3. Other freight is stacked on a reel breakdown of the drum occurs, the
cable is immediately exposed to
4. Nails have been driven into reel damage. Cables damaged during
flanges to secure shipping handling & storage can cause
blocks service failures when the subject
cable is put to use.
5. A reel flange is damaged
Thus the following is a list of Do’s
6. A cable covering is removed,
and Don’ts that should be
stained or damaged
followed while handling and
7. A cable end seal is removed or storing the cables before it is put
damaged. A reel has been to use.
dropped (hidden damage
likely)

Do’s Don’ts
When off loading reels from a truck, Never drop reels. If reels must be rolled,
lower reels carefully using a hydraulic roll in opposite direction of the cable
gate, hoist or forklift truck wraps to keep cable from loosening on
the reel.

If a fork lift is used, approach the reel Do not allow the lift forks to contact the
from the flange side. Position the forks cable. Care must be taken by the fork lift
such that the reel is lifted by both operator not to make sudden turns or
reel flanges. Also Consideration stops.
should be given to, Traffic patterns
during off-loading & damage dur- ing
the time in storage

Cable reels should be stored on Multiple reels stacked on top of each

hard sur- faces resting on the other (“Pancake” storage) is not
flanges edge (flanges vertical). Align recommended for cable drums. The
reels flange to flange and, if weight of the stack can total thousands of
possible, arrange so that first in is kgs. creating an enormous load on the
first out. bottom reel. Also, damage to the reel and/
or cable will likely occur when the reel is
flipped for transit. A concentration of
stress on the reel flange may cause it to
break and subsequently damage the
cable.

27
When using a hoist, install a This may lead to the bending of the reel
mandrel through the reel arbor flanges and mashing the cable
holes and attach a sling. Use a
spreader bar approximately 6 inches
longer than the overall reel width
placed between the sling ends just
above the reel flanges.
Handling, Storage and Laying of Polycab Cables

C. PRE- INSTALLATION 5. Under no circumstances the

To ensure safety during cable cable winding shall be lifted off a
installation, following shall be coil or drum lying flat at the
checked prior to installation. flanges. This would cause
1. The cable selected is proper serious twist and damages.
for designed application. 6. Suitable protection shall be
2. The cable has not been provided to the cables against
damaged in transit or storage. mechanical damages, it includes
Review all applicable state and covers, pipes etc.
national codes to verify that the
cable chosen is appropriate for E. RECOMMENDED
the job. Also consult your local MINIMUM BENDING RADIUS
electricity authority. Next, you must
identify any existing cable damage
FOR HEAVY DUTY CABLES.
and prevent any further damaged Single Core : 20
from occurring. This is done
through proper cable inspection, x D Multicore :
handling and storage. 15 x D
D. INSTALLATION & LAYING Where D= Diameter of cable in mm
Mechanical stresses during
installation are generally more F. RECOMMENDED
severe than those encountered SAFE PULLING FORCE
while in service. Thus care should WITH STOCKINGS:
be taken as regards to the following a) For Unarmoured Cable : P = 5 D2
while installation and laying of
cables. b) For Armoured Cable : P = 9 D2
1. Polycab recommend the Where P = Pulling Force
laying and installation of Where D = Diameter of cable in mm
cables as per IS: 1255/84.
2. Care shall be taken during G. RECOMMENDED SAFE
laying to avoid sharp bending, PULLING FORCE WHEN PULLED
and twisting. WITH PULLING EYE :
3. Cable shall be un wound from the
drum by lifting the drum on the a) For Aluminium Conductor : 30 N/mm2
center
b) For Copper Conductor : 50 N/mm2
4. Shaft supported both ends
with suitablejacks / stands.

DO NOT ATTEMPT “COILING” OF CABLE ON THE

GROUND

ON THE GROUND CABLE CAN BE FLAKED IN A FIGURE OF EIGHT

FORMATION

29
 Note: R Minimum Permissible bending radius of
cable.
28
 Production Facilities at Daman Factory
POLYCAB REGIONAL OFFICES
CHENNAI : Old No. 5/2, New No.9/2 Gopalkrishna Road, T-Nagar, CHENNAI - PUNE - 01. Tel: 0265 3252825 • Fax: 0265 3252825 • Email :
600 017. Tel: 044 42022775 / 28152725 • Fax: 044 42022774 • Email : pune@polycab.com
chennai@polycab.com BANGALORE : 104/6, 5th Cross, 5th Block, Rajajinagar, BANGALORE
BARODA : 9, Khushbu Corner, 56, Vishwas Colony, Alkapuri, BARODA - - 560 010. Tel: 080 23102172 • Fax: 080 23102071 • Email :
390 005. karnataka@polycab.com
Tel: 0265 3252825 / 3083838 • Fax: 0265 3083366 • Email :
gujarat@polycab.com
PUNE : A7, Akshay CHS, South Koregaon Park, Opp Seasons Service Apt.
SECUNDERABAD : 401, A, Suryakiran Complex, Sarojini Devi Road,
SECUNDERABAD - 500 003.
Tel: 040 66326228 • Fax: 040 66326229 • Email : andhra@polycab.com
DELHI : 901-B, 909, 9th Floor, Devika Towers, Nehru Place, NEW DELHI -
110 019. Tel: 011 26453056/57 • Fax: 011 26453058 • Email :
north@polycab.com
KOLKATTA : 1st Floor, 34, Dr. Meghnad Saha Sarani, (Formally Southern
Avenue), Kolkata-700 029. • Email: kolkatta@polycab.com
 Wiring the World

WIRES & CABLES

Polycab Wires PVt. ltd.

(an ISO 9001:2000 Company)

Regd. & Head office :

Polycab House, 771, Pandit Satawalekar Marg,
Mahim (W), Mumbai 400 016.
Tel. : 91-22-2432 7070 - 4, 2436 2199, 2432 9118
Fax : 91-22-2432 7075
E-mail :
info@polycab.com Website
: www.polycab.com
POLYCAB WIRES PVT LTD
TECHNICAL DETAILS

PVC WIRES &

FLEXIBLES
POLYCAB WIRES PVT LTD. 1 of
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 "POLYCAB" PLAIN COPPER CONDUCTOR, PVC INSULATED UNSHEATHED 650 /
1100 V, SINGLE CORE CABLE FOR PANEL BOARD WIRING AS PER IS : 694 /
1990 WITH ISI MARK (UPTO 50 SQ.MM)

MAX.DC
CONDUCTOR INSULATION CABLE CURRENT
AREA IN RESISTANCE
CONSTRUCTION THICKNESS DIA RATING IN
SQ.MM OHM/KM AT
IN GENERAL IN MM (APPX.) AMP.
20 DEGC
0.50 16/0.20 39.00 0.60 2.20 4
0.75 24/0.20 26.00 0.60 2.50 7
1.00 32/0.20 19.50 0.60 2.60 12
1.50 30/0.25 13.30 0.60 2.90 16
2.50 50/0.25 7.98 0.70 3.50 22
4.00 56/0.30 4.95 0.80 4.30 29
6 84/0.30 3.300 0.80 5.30 37
10 140/0.30 1.910 1.00 6.70 51
16 126/0.40 1.210 1.00 8.20 68
25 196/0.40 0.780 1.20 10.00 86
35 276/0.40 0.554 1.20 11.3 110
50 396/0.40 0.386 1.40 13.5 145
NOTE: Cable above 50 sq.mm are not covered by IS : 694 But are as per IS :
2465
70 360/0.50 0.272 1.60 15.5 161
95 485/0.50 0.206 1.80 18.5 200
120 608/0.50 0.161 2.00 20.9 225
150 750/0.50 0.129 2.00 22.5 240
185 925/0.50 0.106 2.20 24.6 300
240 1221/0.50 0.0801 2.20 27.6 425
300 1527/0.50 0.0641 2.40 32.2 475
400 2036/0.50 0.0486 2.60 35.7 550

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"POLYCAB" PLAIN COPPER CONDUCTOR, PVC INSULATED AND SHEATHED 650 / 1100 V, MULTICORE FLEXIBLE CABLES AS PER IS : 694/1990
WITH ISI MARK

MAX. DC INSULATION
COND. CORE SHEATH THICKNESS IN MM OVERALL DIAMETER IN MM CURRENT
AREA IN CONSTRUCTION RESISTANCE THICKNESS
DIA. IN DIA. NOMINAL APPROX. RATING
SQ.MM NO./DIA. OHM/KM AT NOMINAL
MM MM AMP.
20 DEG.C MM 2 core 3 core 4 core 2 core 3 core 4 core

0.50 16/0.2 0.94 39.00 0.60 2.20 0.90 0.90 0.90 6.20 6.60 7.20 4
0.75 24/0.2 1.20 26.00 0.60 2.50 0.90 0.90 0.90 6.80 7.20 7.90 7
1.00 32/0.2 1.34 19.50 0.60 2.60 0.90 0.90 0.90 7.00 7.50 8.10 12
1.50 30/0.25 1.64 13.30 0.60 2.90 0.90 0.90 1.00 7.60 8.10 9.00 16
2.50 50/0.25 2.08 7.98 0.70 3.50 1.00 1.00 1.00 9.00 9.60 10.50 22
4.00 56/0.3 2.61 4.95 0.80 4.30 1.00 1.00 1.00 10.60 11.30 12.40 29

"POLYCAB" PLAIN COPPER CONDUCTOR, PVC INSULATED AND SHEATHED 650 / 1100 V, MULTICORE FLEXIBLE CABLES AS PER IS : 694/1990
WITH ISI MARK

MAX. DC INSULATION
COND. CORE SHEATH THICKNESS IN MM OVERALL DIAMETER IN MM CURRENT
AREA IN CONSTRUCTION RESISTANCE THICKNESS
DIA. IN DIA. NOMINAL APPROX. RATING
SQ.MM NO./DIA. OHM/KM AT NOMINAL
MM MM AMP.
20 DEG.C MM 2 core 3 core 4 core 2 core 3 core 4 core

6.00 84/0.3 3.5 3.30 0.80 5.10 1.15 1.15 1.40 12.60 13.40 15.20 37
10.00 140/0.3 4.60 1.91 1.00 6.60 1.40 1.40 1.40 16.00 17.00 18.80 51
16.00 126/0.4 6 1.21 1.00 8.00 1.40 1.40 1.40 18.80 20.10 22.20 68
25.00 196/0.4 7.6 0.78 1.20 10.00 2.00 2.00 2.00 24.00 25.60 28.20 86
35.00 276/0.4 8.7 0.554 1.20 11.10 2.00 2.00 2.00 26.30 28.00 31.00 110
50.00 396/0.4 10.6 0.386 1.40 13.40 2.00 2.00 2.00 30.90 33.00 36.50 145
70.00 360/0.5 12.3 0.272 1.40 15.10 2.00 2.20 2.40 34.20 37.00 41.00 215
95.00 485/0.5 14.7 0.206 1.60 17.90 2.20 2.40 2.40 40.20 43.50 47.80 260

POLYCAB WIRES PVT LTD. 3 of

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 "POLYCAB" MULTICORE ROUND FLEXIBLE CABLES (6 CORES TO 19 CORES) GENERALLY AS PER IS : 694/1990

Area Sq.mm 0.50 0.75 1.00 1.50 2.50 4.00

General Construction no./dia 16/0.2 24/0.2 32/0.2 30/0.25 50/0.25 56/0.3
Conductor Dia. In MM 0.94 1.20 1.34 1.64 2.08 2.61
Avg. Insu. Thickness in MM 0.60 0.60 0.60 0.60 0.70 0.80
Core Dia in MM 2.20 2.50 2.60 2.90 3.50 4.30
No. of Cores
6 Avg. Sheath thickness MM 0.90 1.00 1.00 1.00 1.10 1.20
App. Overall Dia MM 8.50 9.50 9.80 10.70 12.70 15.30
7 Avg. Sheath thickness MM 0.90 1.00 1.00 1.00 1.10 1.20
App. Overall Dia MM 8.50 9.50 9.80 10.70 12.70 15.30
8 Avg. Sheath thickness MM 1.00 1.00 1.00 1.10 1.20 1.30
App. Overall Dia MM 9.30 10.40 10.70 11.90 14.10 16.90
10 Avg. Sheath thickness MM 1.00 1.10 1.10 1.10 1.30 1.40
App. Overall Dia MM 10.80 12.20 12.60 13.80 16.60 20.00
12 Avg. Sheath thickness MM 1.00 1.10 1.10 1.10 1.30 1.40
App. Overall Dia MM 11.20 12.60 13.00 14.30 17.20 20.70
14 Avg. Sheath thickness MM 1.10 1.10 1.10 1.20 1.30 1.40
App. Overall Dia MM 12.00 13.30 13.70 15.20 18.10 21.80
16 Avg. Sheath thickness MM 1.10 1.20 1.20 1.20 1.40 1.50
App. Overall Dia MM 12.60 14.20 14.60 16.00 19.30 23.20
19 Avg. Sheath thickness MM 1.10 1.20 1.30 1.30 1.40 1.50
App. Overall Dia MM 13.20 14.90 15.60 17.10 20.30 24.50
24 Avg. Sheath thickness MM 1.20 1.30 1.30 1.40 1.40 1.50
App. Overall Dia MM 15.60 17.60 18.20 20.20 23.80 28.80
30 Avg. Sheath thickness MM 1.30 1.30 1.30 1.40 1.40 1.50
App. Overall Dia MM 16.80 18.70 19.30 21.50 25.70 30.60
Max. Conductor Resistance in 39.00 26.00 19.50 13.30 7.98 4.95
Ohm/km at 20 deg.C
Recommended Current Rating 4 7 12 16 22 29
in AMP

POLYCAB WIRES PVT LTD. 4 of

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AERIAL BUNCHED
CABLES

POLYCAB WIRES PVT. LTD.

HICO HOUSE, 1st FLOOR,
PANDIT SATWALEKAR MARG,
MAHIM, MUMBAI – 400 016
TEL: 91-22-24327070, FAX:91-22-24327075
E-mail: polycab@vsnl.com
Internet: www.polycab.com
POLYCAB WIRES PVT. LTD. AERIAL BUNCHED CABLES

ABOUT US
From a modest beginning with Conductors, Compounds and Wires &
Cables, almost three decades ago, the Polycab Group Set up a State of
Art manufacturing facilities at Daman in 1997, to address key market
determinants. Starting the project from scratch Polycab was able to
design a manufacturing facility around State of Art disciplines of
Computer integrated manufacture .The Quality & Manufacturing
setup is sourced out from the World renown Machinery and
Technology Suppliers with constant upgradations and expansions.

At POLYCAB, We study the requirements of the penultimate users

with our commitment for Quality and Value. These are converted
into process specifications based on Indian & International
Standards.

In an on going effect to improve Customer satisfaction POLYCAB

offers a variety of services: -

 Commercially Competitive Prices.

 Reliable & Consistent quality.
 Reliable & just in time delivery.
 Product development for a changing market
 A target stocking policy.
 Technical Support for Applications /Projects.

POLYCAB derives its strengths from its Customers. The Growth of

latter is a prerequisite to the growth of the Company and hence
Customer satisfaction is its prime Objective. Over the years sincere
service and dedication of its Customers has earned the Company
distinguished clientele Which includes leaders in Sectors like Utilities,
Power Distribution, Oil Refineries, Oem’s, EPC Contractors, Steel &
Metal, Cement, Petroleum, Chemical, Atomic Energy & Nuclear
Power etc. etc.

For any Company the key to establish itself in the export market is
QUALITY. Not surprisingly, considering its quality conscious
approach towards manufacturing Polycab enjoys a good reputation
in the global market.

Now the company has monthly manufacturing capacity to Process

over 1500 Tons of Rod Copper & Tinned Copper, 1000 Tons of Alloy
& Aluminium and over 800 Tons of fine tinned & Bare Copper
Wires, to produce a wide range of Conductors for H.T. & L.T. Power
Cables, Control Cables, Instrumentation, House Wires, Flexibles,
Submersible & Welding Cables, FS Cables, Aerial Bunched Cables,
AAC, AAAC, ACSR Bare and Earthing Conductors.

Our constant efforts to incorporate latest efficiency mechanism in our

manufacturing and service are the key factors of “Adding Value
through Conductors & Cables”. Our plant at Daman offers NIL sales
tax to the customers and a wide marketing network to cater domestic
and exports requirements.

With offices, personnel, distributors, dealers, stockists throughout the

Country, Polycab offers the highest level of Customer Service.

Page 1 of 12
POLYCAB WIRES PVT. LTD. AERIAL BUNCHED CABLES

AERIAL BUNCHED CABLES FOR OVERHEAD DISTRIBUTION

INTRODUCTION

Aerial Bunched Cable (ABC) is a very novel concept for Over Head power
distribution. When compared to the conventional bare conductor over head distribution
system, ABC provides higher safety and reliability, lower power losses and ultimate
system economy by reducing installation, maintenance and operative cost. This system is
ideal for rural distribution and specially attractive for installation in difficult terrains such
as hilly areas, forest areas, coastal areas etc.

ABC is also considered to be the best choice for power distribution congested urban
areas with narrow lanes and by-lanes. In developing urban complex, ABC is the better
choice because of flexibility for rerouting as demanded by changes in urban development
plan.

CONSTRUCTION OF ABC

XLPE/HDPE insulated power conductors of Aluminium (Neutral conductor and street

lighting conductors if and when necessary) are laid together (twisted) around a high
tensile stranded and galvanized steel (Aluminium Alloy may be used) insulated or bare
messenger wire to form the Aerial Bunched Cable. This assembly is directly strung on to
distribution pole/towers by means of standard hardwares available in the market but care
shall be taken to render the messenger wire completely insulated from earthing at any
point of distribution in case of HT ABC.

The XLPE (Cross-linked Polyethylene) insulation is black in colour and is stabilized

against deterioration caused by exposure to direct sunlight and ultraviolet radiation.
XLPE is cross-linkable low density polyethylene which is made thermoset by special
formulation from base polymer of thermoplastic low density polyethylene. XLPE
combines the best electrical properties of LDPE and superior thermo mechanical
properties.

MATERIALS

(i) Aluminium conductors conform to IS:8130 (Class-II)

(ii) Stranded high tensile galvanized steel messenger wire conforms to IS:398
(Part-2). Alternatively Aluminium Alloy messenger wire conforms to IS:398
(Part-IV)
(iii) XLPE and HDPE insulation of power conductors conform to IS: 7098 (Part I
& II) and IS: 6474 respectively.

Since, the tension from the current carrying conductor is totally removed by introduction
of messenger wire the operating temperature of the conductor is 900 C as against 750C of
the bare conductor under tension thereby allowing ABC to carry current equivalent to that
of bare conductor of the same size.

Page 2 of 12
POLYCAB WIRES PVT. LTD. AERIAL BUNCHED CABLES

STRINGING

No difficulty is envisaged during stringing of ABC in the conventional method but care
shall be taken that insulated conductors do not get damaged during installation. Dragging
the ABC on the ground is to be avoided. Tension to be applied during stringing shall be
25% of the breaking load of the messenger wires. This will allow line to have sag within
specified limit of 1.5% of the span at the lowest ambient temperature.

JOINTING

While mid-span jointing permissible for LT ABC system by conventional technique, our
recommendation will be to draw the line in such a way as to bring the joints at the
supports. Mid-span jointing is not at all recommended in the case of HT lines our
recommendation is for outdoor type HV terminations only. Under unavoidable
circumstances, line tapping at the support points may be allowed through suitably
designed clamp connectors/PG clamps. The semiconducting screen continuity shall be
maintained at all joints as far as possible to avoid fluctuations during system disturbances.
The 3-phase screens may be shorted and earthed through suitable non-linear surge
arrestor. Attempting to make a tap off from power conductors in the region where
catenary is under tension is not recommended.

APPLICATION

ABC can be conveniently used:

a) as replacement of bare lines in Rural Areas, in woods and in other localities &
narrows streets where the space is limited.
b) as replacement of bare lines where reliability of supply is of prime importance.
c) as replacement of bare lines where high degree of stability of supply voltage is of
importance.
d) in hilly terrains where cost of erection of overhead lines or under ground cable
becomes very high.
e) as reinforcement of existing system without increasing voltage.
f) for temporary supplies.

ADVANTAGES

In comparison to bare overhead power distribution lines, ABC has very high
reliability in maintaining services because power and neutral conductors are insulated
with the best dielectric medium, resulting in the following advantages:

1) Less fault rate on account of good protection against line and ground faults by
high winds or falling trees or birds especially in hilly areas & forests as
encountered in rural distribution networks.

2) High insulation resistance to earth in all seasons and polluted atmospheres.

Negligible leakage currents and low losses.

3) Multiple circuits of Power and Telephone cables could be strung in the same set
of poles or any other supports like walls etc.

Page 3 of 12
 POLYCAB WIRES PVT. LTD. AERIAL BUNCHED CABLES

4) Better adaptability to run concurrently with existing over-head bare conductor

system without any interference.

5) High capacitance and low inductance leading to low impedance of lines.

6) Lower voltage drop, higher current capacities. VIS-À-VIS Better Voltage

Regulation.

7) Longer spans and longer distance lines are possible with better system stability.

8) ABC cables are much safer than bare Conductors.

9) It can be over hung in dense vegetation and forests.

10) Additional connections can be easily and quickly made with hot-line connectors.

11) Total lines costs are reduced.

12) Maintenance is very easy.

COMPARATIVE COSTS INDEX:

System Cost Index

U.G.Cable System 1.00

O.H.Bare Conductor System 0.35

ABC System 0.50

RELIABILITY, SAFETY AND FLEXIBILITY:

ABC Cables are highly reliable and insulation has been developed to withstand heat, cold
and intense sunlight. Disturbance and faults occur five to ten times more often in open
wire lines than in ABC lines. There is no risk in touching the live cable and the insulation
reduces the number of short circuits and over-voltages in overhead cables during
thunderstorms. Few hardware accessories are needed as each one can be used with many
different sizes of cable. This makes installation and storage easier. Streets can easily be
get lit at little extra cost by using the ABC cables that have an extra conductor for
lighting. The cable can be supplied with one or two insulated conductors for street
lighting.

Page 4 of 12
POLYCAB WIRES PVT. LTD. AERIAL BUNCHED CABLES

EXPERIENCE:

After extensive research Polycab has successfully developed and introduced Aerial
Bunched Conductor Cables, and have already achieved technical competence,
manufacturing ability, and marketing experience by supplying ABC cables to the
following Customers: -

1. BSES LTD (for Gridco – Orissa)

2. North Delhi Power Ltd - Delhi

TAILOR MADE DESIGN

POLYCAB have recognized the need for H.T & L.T ABC cables in the emerging market
due to thrust in the Transmission & Distribution network revamping programme by Govt.
of India. We can interact with you to design for you ABC cables to meet your specific
requirements.

HARDWARE AND ACCESSORIES:

The hardware and accessories for AB cables are made by various reputed manufacturer
and is easily available in India. They are similar to the standard hardware available for
Bare conductor overhead distribution lines.

APPROVAL & CERTIFICATION

1. BIS License for IS-694-1990 for 1100V Wires & Cables.

2. BIS License for IS- 1554.

3. BIS License for IS-7098 PART I & II

4. BIS License for Overhead Aluminium Conductor (IS-398) and

Copper Conductor (IS-282) and IS-8130 for other Conductors.

5. Quality System Certification upgradation from ISO- 9002 to ISO-

9001 by Underwriters Laboratories, in final stage

6. Safety Certification for various conductors as per BASEC are

under finalisation.

Page 5 of 12
POLYCAB WIRES PVT. LTD. AERIAL BUNCHED CABLES

QUALITY SETUP

Conductors are generally the only means to transport current or signals with
required safety norms. Therefore the material of its construction, purity and other
important aspects of metallurgy are the critical factors to source the wire rods. We have
latest 3-D profile die checking and refurbishment system. The sourcing of wire drawing,
lubricant is from company like Houghton Italy and intensive inspection testing
Conductor to ensure quality.
At Polycab, We do;

QA IN PLANNING QA IN RAW MATERIALS QA ONLINE

Customer requirements, The raw materials are The company has

alongwith the orders are procured from the best online computerised
taken into quality sources from the domestic control system on all its
planning with due care and global market. These critical processes and a
for designing, sources are selected on the team of online testing
manufacturing, testing based on the company’s engineers to ensure the
and performance stringent quality vendor consistency in quality
aspects. evaluation/ continuous
assessment and testing.

TESTING
Each consignment of conductor & wires is
exhaustively tested before dispatch clearance, by
highly qualified, Experienced and dedicated testing
team.
The testing setup is broadly classified as follows

(1) R.M. Testing Labs.

(2) Routine Testing for Conductor, LT wires & Cables
(3) Type Testing Labs include FR/FS/FRLS testing

All the laboratories are equipped with the modern

testing Instruments. All the instruments are
under strict Calibration and environment control.

Page 6 of 12
POLYCAB WIRES PVT. LTD. AERIAL BUNCHED CABLES

TECHNICAL PARTICULARS
LT Aerial Bunched Cable 1100 Volts (3 1/2 core). Reference standard: Generally to IS: 7098 (1)88.
3x25 3x35 3x50 3x70 3x95
Sl + + + + +
No. Description 1x16 1x16 1x25 1x35 1x50
+ + + + +
1x35 1x35 1x35 1x35 1x55
1. Power/Neutral core:
1.2 Conductors
a) Nom. cross sectional area
(i) Power cores (mm2) 25 35 50 70 95
(ii) Neutral core (mm2) 16 16 25 35 50
b) Max.D.C.resistance
conductor at 20 C
(i) Power cores (Ohm/Km) 1.20 0.868 0.641 0.443 0.320
(ii) Neutral core (Ohm/Km) 1.91 1.910 1.200 0.868 0.641
c) Approx. diameter of
Conductor
(i) Power cores (mm) 6.2 7.3 8.35 10.1 12.00
(ii) Neutral core (mm) 5.1 5.1 6.20 7.30 8.35

Insulation:
1.2 Minimum thickness:
(i) Power cores (mm) 0.9 0.9 1.0 1.1 1.1
(ii) Neutral core (mm) 0.7 0.7 0.9 0.9 1.0
2. Messenger Wire (Bare):
(i) Nom. cross sectional area (Sq. mm) 35 35 35 55 55
(ii) Approx. breaking load (KN) 41 41 41 62 62
3. Current ratings:
Continuous current carrying
Capacity of cable in Air at
Ambient temp. 40 0 C (Amp.) 99 122 149 190 235
4. Approx. weight (kg./km.) 580 665 810 1165 1430
5. Number of cores:
(i) Power cores (No.) : 3
(ii) Neutral core (No.) : 1
(iii) Bare messenger (No.) : 1
6. Derating factor:
Derating factors for variation
In air Temp.
Air Temp (0 C) 30 35 40 45 50 55
Rating factor 1.12 1.06 1.0 0.94 0.88 0.83
7. (i) Identification of Power core: By providing ridges on the insulation:
(ii) Laying: Three power cores and one neutral core shall be
suitably twisted around bare H.T. Steel
Messenger./ AAAC
8. Details of the Power/Neutral core:
(i) Conductor:
(a) Material Aluminium to IS: 8130/84
(b) Flexibility class as per IS: 8130/84 Class-2
(c) Form of conductor Compacted circular
(ii) Insulation:
(a) Material Cross linked Polyethylene to IS: 7098(I)/88
(b) Colour of Insulation Black
9. Details of the Messenger wire (Bare)
(i) Material ACSR/AAAC Conductor to IS: 398(II) & (IV)
respectively.
(ii) Form of conductor Stranded circular/compacted circular.

Page 7 of 12
POLYCAB WIRES PVT. LTD. AERIAL BUNCHED CABLES

TECHNICAL PARTICULARS
LT Aerial Bunched Cable 1100 Volts (4 core). Reference standard: Generally to IS:7098(1)88.
3x25 3x35 3x50 3x70 3x95
Sl + + + + +
No. Description 1x25 1x35 1x50 1x70 1x95
+ + + + +
1x35 1x35 1x35 1x55 1x55
1. Power/Neutral core:
1.1 Conductors
a) Nom. cross sectional area
(i) Power cores (mm2) 25 35 50 70 95
(ii) Neutral core (mm2) 25 35 50 70 95
b) Max. D.C. resistance
conductor at 200 C
(i) Power cores (Ohm/Km) 1.20 0.868 0.641 0.443 0.320
(ii) Neutral core (Ohm/Km) 1.20 0.868 0.641 0.443 0.320
c) Approx. diameter of
Conductor
(i) Power cores (mm) 6.2 7.3 8.35 10.1 12.0
(ii) Neutral core (mm) 6.2 7.3 8.35 10.1 12.0
1.2 Insulation:
Minimum thickness:
(i) Power cores (mm) 0.9 0.9 1.0 1.1 1.1
(ii) Neutral core (mm) 0.9 0.9 1.0 1.1 1.1
2. Messenger Wire (Bare):
(i) Nom. cross sectional area (Sq. mm) 35 35 35 55 55
(ii) Approx. breaking load (KN) 41 41 41 62 62
3. Current ratings:
Continuous current carrying
capacity of cable in Air at
Ambient temp. 400 C (Amp.) 99 122 149 190 235
4. Approx.weight (kg./km.) 610 725 880 1270 1570
5. Number of cores:
(i) Power cores (No.) : 3
(ii) Neutral core (No.) : 1
(iii) Bare messenger (No.) : 1
6. Derating factor:
Derating factors for variation
In air Temp.
Air Temp (0 C) 30 35 40 45 50 55
Rating factor 1.12 1.06 1.0 0.94 0.88 0.83
7. (a) Identification of Power core: By providing ridges on the insulation
(b) Laying Three power cores and one neutral core shall
be suitably twisted around bare H.T.Steel
Messenger. /AAAC.
8. Details of the Power/Neutral core:
(i) Conductor:
(a) Material Aluminium to IS: 8130/84
(b) Flexibility class as per IS: 8130/84 Class-2
(c) Form of conductor Compacted circular
(ii) Insulation:
(a) Material Cross linked Polyethylene to IS: 7098(I)88
(b) Colour of Insulation Black
9. Details of the Messenger wire (Bare)
(i) Material ACSR/AAAC. Conductor to IS: 398 (II) &
(IV) respectively
(ii) Form of conductor Stranded circular/compacted circular.

Page 8 of 12
 POLYCAB WIRES PVT. LTD. AERIAL BUNCHED CABLES

TECHNICAL PARTICULARS
LT Aerial Bunched Cable 1100 Volts (5 core) with Street Lighting Conductor. Reference Standard:
Generally to IS:6474-71
3x16 3x25 3x35 3x50 3x70 3x95 3x120
+ + + + + + +
Sl. 1x16 x16 1x16 1x16 1x16 1x16 1x16
No. Description + + + + + + +
1x25 1x25 1x25 1x35 1x50 1x70 1x70
1. Power /Neutral core:
1.1 Conductors
(a) Nom. cross sectional area
(i) Phase Conductor (mm2) 16 25 35 50 70 95 120
(ii) Street Lighting Conductor (mm2) 16 16 16 16 16 16 16
(b) Max. D.C. resistance
conductor at 200 C
(i) Phase Conductors (Ohm/Km) 1.91 1.20 0.868 0.641 0.443 0.320 0.253
(ii) Street Lighting (Ohm/Km) 1.91 1.91 1.910 1.910 1.910 1.910 1.910
(c) Approx. diameter of conductor
(i) Phase Conductor (mm) 4.4 5.5 6.8 7.9 9.6 11.3 12.7
(ii) Street Lighting conductor (mm) 4.4 4.4 4.4 4.4 4.4 4.4 4.4
1.2 Insulation:
Minimum thickness:
1.0 1.0 1.0 1.2 1.4 1.4 1.6
(i) Phase Conductor (mm)
1.0 1.0 1.0 1.0 1.0 1.0 1.0
(ii) Street Lighting Conductor (mm)
2. Messenger Wire (Bare)
(i) Nom. cross sectional area (Sq.mm) 25 25 25 35 50 70 70
(ii)Approx. breaking load (KN) 7.4 7.4 7.4 10.3 14.7 20.6 20.6
3. Current ratings:
Continuous current carrying
Capacity of cable in Air at
Ambient temp. 400C (Amp.) 51 70 86 105 130 155 180
4. Approx.weight (Kg./Km) 310 390 490 640 890 1180 1430
5. Number of cores:
(i) Power cores (No.) :
(ii) Neutral core (No.) 3
(iii) Bare messenger (No.) : 1
: 1
6. Derating factor:
Derating factors for variation
In air Temp.
Air Temp (0C) 30 35 40 45 50 55
Rating factor 1.12 1.06 1.0 0.94 0.88 0.83
7. (a) Identification of Power cores: By providing ridges on the insulation
(b) Laying Three power cores and one neutral Core shall be suitably
twisted around Bare AAAC Messenger.
8. Details of the Power/Neutral core:
(i) Conductor:
(a) Material Aluminium to IS:8130/84
(b) Flexibility class as per IS: 8130/84 Class-2
(c) Form of conductor Compacted circular
(ii) Insulation
(a) Material High Density Polyethylene to IS: 6474 – 1971
(b) Colour of insulation Black
9. Details of the Messenger wire (Bare)
(i) Material All Alloy Aluminium Conductor to IS: 398 (IV)
(ii) Form of conductor Stranded Compacted circular.

Page 9 of 12
POLYCAB WIRES PVT. LTD. AERIAL BUNCHED CABLES

TECHNICAL PARTICULARS
LT Aerial Bunched Cable 1100 Volts (4 core). Reference standard: Generally to IS: 6474-71.
3x16 3x25 3x35 3x50
Sl
+ + + +
No. Description
1x25 1x25 1x25 1x35
1. Power/Neutral core:
1.1 Conductors
a) Nom. cross sectional area
(i) Power cores (mm2) 16 25 35 50
(ii) Neutral conductor (mm2) 25 25 25 35
b) Max. D.C. resistance
conductor at 200 C
(i) Phase Conductor (Ohm/Km) 1.91 1.20 0.868 0.641
(ii) Neutral Conductor (Ohm/Km) 1.38 1.38 1.38 0.968
c) Approx. diameter of
conductor (Compacted)
(i) Phase conductor (mm) 4.4 5.5 6.8 7.9
(ii) Neutral Conductor (mm) 5.8 5.8 5.8 6.8
1.2 Insulation:
Minimum thickness:
1.0 1.0 1.0 1.2
(i) Phase Conductor (mm)
2. Messenger Wire (Bare)
(i.) Nom. cross sectional area (Sq. mm) 25 25 25 35
(ii.) Approx. Tensile Strength (KN) 7.4 7.4 7.4 10.3
3. Current ratings:
Continuous current carrying
Capacity of cable in Air at
Ambient temp. 400 C (Amp.) 60 76 92 110
4. Approx.weight (kg./km.) 250 330 430 580
5. Number of cores:
(i) Power cores (No.) : 3
(ii) Neutral messenger core (No.) : 1
6. Derating factor:
Derating factors for variation I
In air Temp.
Air Temp (0 C) 30 35 40 45 50 55
Rating factor 1.12 1.06 1.0 0.94 0.88 0.83
7. (i) Identification of Power core: By providing ridges on the insulation
(ii) Laying: Three power cores and one neutral core shall be
suitably twisted around bare AAAC Messenger.
8. Details of the Power/Neutral core:
(i) Conductor
(a) Material Aluminium to IS:8130/84
(b) Flexibility class as per IS: 8130/84 Class-2
(c) Form of conductor Compacted circular
(ii) Insulation:
(a) Material High Density Polyethylene to IS: 6474 –1971
(b) Colour of insulation Black
9. Details of the Messenger wire (Bare)
(i) Material All alloy aluminium Conductor to IS: 398 (IV)
(ii) Form of conductor Stranded compacted circular.

Page 10 of
12
POLYCAB WIRES PVT. LTD. AERIAL BUNCHED CABLES

FINISHED AERIAL BUNCHED CABLE TESTING

Prior to despatch, cable is subjected to rigorous testing. Test procedures followed at our
works are according to various national & International specifications and are covered in
this paper.

Following tests are performed on Aerial Bunched Cables:-

1. Test on Phase/Street lighting conductor

TESTS METHOD OF TESTING

a) Tensile test IS: 10810 pt -2

b) Wrapping test IS: 10810 pt -3

c) Conductor Resistant Test IS: 10810 pt -5

d) Test for thickness of insulation IS: 10810 pt -6

e) Physical test for polyethylene insulation

(i) Tensile strength & Elong. Test IS: 10810 pt -7
(ii) Melt flow Index IS: 10810 pt - 23
(iii) Vicat softening Point IS: 10810 pt - 22
(iv) Carbon Black Content & dispersion IS: 10810 pt - 32
(v) Colour factness IS: 10810 pt - 18
(vi) Environmental stress cracking IS: 10810 pt - 29
(vii) Bleeding & Blooming IS: 10810 pt - 19
(viii) Volume Resistivity test IS: 10810 pt - 43
(f) High Voltage test including water IS: 1596
immersion test.

2. Test for messenger conductor: -

(a) Breaking load test IS: 398 (pt-IV)
(b) Elongation test IS: 398 (pt-IV)
(c) Resistance test IS: 398 (pt-IV)

3. Dimentional test as per the parameters specified in the technical particulars.

4. Bending test on completed cable shall also as performed. The diameter of

mandrel shall be 10 (D+d)

Where D = Overall diameter of the cable

D = Dia over conductor.

Page 11 of 12
POLYCAB WIRES PVT. LTD. AERIAL BUNCHED CABLES

PROCESS FLOW CHART FOR MANUFACTURE OF

AERIAL BUNCHEDCABLES

A1. Rod A1. Alloy Rod

Wire Drawing Intermediate Wire Drawing

Stranding Solution Treatment

1 2
Extrusion (Black HDPE/XLPE) Wire Drawing

Spark Testing Ageing

Stranding

Laying

Testing
3
Packing

Dispatch

1. Manufacture of phase/street lighting conductor.

2. Manufacture of messenger conductor.

3. Twisting of cores for manufacture of Aerial Bunched Cables.

Page 12 of
12
 IS 7098 (Part I)

Details make the Difference

©
XLPE INSULATED
HEAVY DUTY
WIRES & CABLES CABLES 650/1100V.
P R O D U C T R A N G E

■
L.T. PVC & XLPE POWER CABLES WITH
COPPER / ALUMINIUM CONDUCTOR (1100 V.
UPTO 4 CORE X 630 SQ. MM., 1 CORE X
1000 SQ. MM.)
■
L.T PVC & XLPE CONTROL CABLES
(1100 V. UPTO 61 CORE X 1.5 & 2.5 SQ.MM.)
■
H.T. XLPE CABLES UPTO 132 kV
■
FIRE SURVIVAL, ZERO HALOGEN CABLES
■
THERMO COUPLE COMPENSATING & EXTENSION
CABLES
■
INSTRUMENTATION CABLES SCREENED /
UNSCREENED
■
FRLS / FR / HR / HFFR / HOFR / RUBBER –
POWER, CONTROL & INSTRUMENTATION
CABLES
■
HT / LT AERIAL BUNCHED CABLES
■
RAILWAY SIGNALLING CABLES
■
TELEPHONE CABLES – DRY & JELLY FILLED
■
ACSR & AAAC CONDUCTORS
■
MINING / WELDING – RUBBER CABLES
■
EPR / SILICONE / HIGH TEMP. CABLES
■
SUBMERSIBLE CABLES
■
COAXIAL CABLES
■
BUILDING WIRES & FLEXIBLES (SINGLE & MULTICORE)
■
LAN CAT-5 / 5E, 6 CABLES
■
PVC PIPES & ACCESSORIES
■
INDUSTRIAL PLUGS & SOCKETS
 ©

Contents
AN ISO 9001:2000 COMPANY

Details make the difference 2

Introduction 3

Advantages of Polycab XLPE Cables & Selection 4

Comparative Current Rating and Short Circuit

5
Rating for XLPE Cable Vis-à-Vis PVC Cables

Technical Data 6-7

Tables 8-19

Rating Factors 20-22

Handling 23-24

1
Details make the difference

THE COMPANY Applications/

POLYCAB, an ISO 9001: 2000 company Projects
is the largest Wire & Cable CUSTOMER
manufacturer in India with a proven FOCUSED
track record of over three decades.
The fastest growing company in the POLYCAB
Indian Cable Industry with derives its
consistent growth of more than strength from
40% per annum for the last 4 years. its
Polycab group has crossed Rs. 2000
crore turnover in the year 2006- 07
and is set to achieve Rs. 3000 crore
turnover in the year 2007 – 08.
From a modest beginning with
Wires and Cables, over three
decades ago Polycab set up State of
Art manufacturing facilities at
Daman in 1996.The last 3
decades have seen the core
business develop along different
product lines: - Low Voltage
Cables, Medium Voltage Cables, Extra
High Voltage Cables, Fire Survival &
Fire Resistant Cables,
Telecommunication Cables, Control &
Instrumentation Cables and Aerial
Bunched Cables. In the
manufacture of cables, a
competitive edge lies not so much
in product innovation as in providing
consistent quality, guaranteeing
reliability and ready availability.
Polycab’s Daman factory was
created to address these key
market determinants. The
manufacturing set up is sourced
out from the world renowned
Machinery and Technology
suppliers with constant upgradation
and expansions.

CUSTOMER SATISFACTION
In an ongoing process to improve
Customer Satisfaction Polycab
offers a variety of services:
• Commercially competitive prices.
• Reliable & consistent quality.
• Reliable & just in time delivery.
• Product development for a
changing market.
• A targeted stocking policy.
• Technical Support for

2
customers. The growth of the latter is a prerequisite to Plants, Distribution Systems,©

the growth of the company and hence customers’ Heavy Industries, Various Utilities,
satisfaction is its prime objective. Over the years The Titans of Indian Industry &
sincere service and dedication to its Customers has Consultants / Specifiers.
earned the Company distinguished Customers which
includes demanding leaders in Sectors like Utilities, DETAILS MAKE THE DIFFERENCE
Power Generation, Transmission & Distribution,
More than 3 decades of experience
Petroleum & Oil Refineries, Oem’s, EPC contractors,
have enabled POLYCAB to
Steel & Metal, Cement, Chemical, Atomic Energy,
develop a specific know how for
Nuclear Power, Consultants & Specifiers etc.
each individual productline.
POLYCAB has highly experienced, qualified and dedicated Attention to details allows the
professionals with strong adherence to the quality company to apply optimum
management system. Polycab has offices all over the technical solutions and material
country and also has a wide network of authorized selections to each and every
distributors and dealers to cater to all the customer different project or application.
segments in India and abroad.
Other available Catalogues:
POLYCAB has earned the trust and reputation in India and Flexible Cables
abroad by winning the customers’ confidence. Several LT PVC Power & Control
thousands kilometers of LT XLPE Cables in the voltage Cables. HT Cables upto
range of 1.1KV have been manufactured and are in
operation in India and abroad. 45KV
EHV Cables upto 132Kv
Polycab LT XLPE Cables are preferred choice in Power Fire Survival Cables.

Polycab Wires Pvt. Ltd. takes every precaution to ensure the information given in this publication
is correct. E & O.E. all information is subject to change without notice.

3
 ©

XLPE Cables
AN ISO 9001:2000 COMPANY

The XLPE insulated heavy duty cables were introduced worldwide in mid
sixties. These cables have overcome the limitations of PVC Insulated Cables such
as thermal degradation, poor moisture resistant and thermoplastic in nature.
The advantages of XLPE Insulated cables in comparison to PVC insulated
cables are as under:
A. Technical Advantages :
1. Higher current rating, higher Short Circuit Rating Approx 1.2 times that of
PVC.
2. Thermosetting in nature.
3. Higher insulation resistance – 1000 times more than PVC cables.
4. Higher resistance to moisture.
5. Better Resistance to surge currents.
6. Low Dielectric Losses.
7. Better resistance to chemicals.
8. Longer service life.
9. Comparatively higher cable operation temperature
90°C and short circuit temperature 250°C.

B. Commercial Advantages:
1. Lower laying cost because of comparatively smaller diameter of cable
and lighter weight*.
2. Lower installation charges as the diameter of cable is comparatively
lesser with smaller bending radius, requiring less space requirement for
laying of cables.
3. **One size lower cable can be used as compared to PVC insulated cable.

* Density of XLPE is lower than PVC

**For longer cable length voltage drop shall be considered

3
Advantages of Polycab XLPE Cables

HIGHER ELECTRICAL STRENGTH RETENTION

HIGHER SHORT CIRCUIT RATING

BETTER ELECTRICAL, MECHANICAL & THERMAL

PROPERTIES

EASY JOINTING & TERMINATION

Selection of Cables

Power Cables are generally selected considering the application.

However, following factors are important for selection of suitable cable
construction required to transport electrical energy from one end to the
other.
1) Maximum operating voltage,
2) Fault Level,
3) Load to be carried,
4) Possible overloading duration & magnitude,
5) Route length and voltage drop.
6) Mode of installation considering installation environment such as ambient
& ground temperature chemical & physical properties of soil.
7) Flame retardant properties.
All sizes of POLYCAB XLPE cables are designed to standard operating conditions in
India and abroad. The standards adopted are considering the geographical/
climatical conditions and general applications of power for utilities, distribution
and generation purposes.
The cables are manufactured conforming to Indian & International cables
specifications for XLPE Insulated cables. Customer specific requirements can

4
 ©
also be met.

5
 ©

Comparative current Rating and Short Circuit

Rating for XLPE Cable Vis-à-vis PVC Cables
AN ISO 9001:2000 COMPANY

COMPARATIVE CURRENT RATINGS OF 650/1100 VOLTS MULTICORE HEAVY DUTY PVC INSULATED CABLES & XLPE INSULATED
CABLES.
(3. 3.5 & 4 Core Unarmoured / Armoured PVC Sheathed Cables with Aluminium Conductor.)

Nominal Size of 3, 3.5 & 4 Core PVC Insulated & Sheathed Cables as per IS 3, 3.5 & 4 Core XLPE Insulated & Sheathed Cables as per IS
cable - 1554 (Part-1) 1988 - 7098 (Part-1) 1988
In Ground In Air Approx Voltage In Ground In Air Approx Voltage
Drop Drop
Sq. mm Amp Amp Mv / amp / mtr Amp Amp Mv / amp / mtr
16 60 51 4.0 73 70 4.20
25 76 70 2.5 94 96 2.70
35 92 86 1.8 113 117 1.90
50 110 105 1.3 133 142 1.40
70 135 130 0.93 164 179 0.99
95 165 155 0.68 196 221 0.72
120 185 180 0.54 223 257 0.58
150 210 205 0.46 249 292 0.48
185 235 240 0.38 282 337 0.39
240 275 280 0.28 326 399 0.31
300 305 315 0.25 367 455 0.26
400 335 375 0.20 420 530 0.21

COMPARISON OF SHORT CIRCUIT RATING FOR 1 SECOND DURATION FOR

* PVC & XLPE Insulated Cables ** with Copper and Aluminium Conductors. (Current in kAmps)
Nominal Size PVC Insulated XLPE Insulated
Sq. mm Copper Aluminium Copper Aluminium
1.5 0.173 - 0.21 -
2.5 0.283 - 0.36 -
4 0.46 0.303 0.57 0.38
6 0.690 0.455 0.86 0.57
10 1.15 0.758 1.40 0.94
16 1.84 1.21 2.30 1.50
* PVC Type ‘A’ Insulation as per IS-5831 ’84.
25 2.88 1.90 3.60 2.40
** PVC Cables as per IS-1554 (Part-1)-1988.
35 4.03 2.65 5.00 3.30
** XLPE Cables as per IS-7098 (Part-1)-
50 5.75 3.79 7.10 4.70 1988.
70 8.05 5.31 10.00 6.60
1) Max. Conductor Temperature
95 10.90 7.20 13.60 9.00
during operation PVC
120 13.80 9.10 17.10 11.30
XLPE
150 17.30 11.40 21.40 14.20
70°C 90°C
185 21.30 14.02 26.40 17.50
240 27.60 18.20 34.30 22.60 2) Max. Conductor Temperature
300 34.50 22.80 42.90 28.30 During Short circuit.
400 46.00 30.40 57.10 37.70 160°C
500 57.50 38.00 71.40 47.20 250°C
630 72.50 47.25 90.00 59.40
Formula relating Short Circuit Rating with duration
800 92.00 60.00 114.30 75.50

It = I sh
6
 t
Where
It = Short Circuit Rating for t
Seconds. t = Duration in seconds
Ish = Short
1000 Circuit rating for75.00
115.00 1 second. 142.90 94.30

5
Technical Data

CAPACITANCE APPROXIMATE CAPACITANCE (Microfarads/ Km) 1.1 KV XLPE CABLES.

Nominal Area Single Core Two Core Three, Three & Half and
of Unarmoured Armoured Four Core
Conductor
1.5 0.19 - 0.051 0.15
2.5 0.24 - 0.058 0.18
4 0.29 - 0.065 0.22
6 0.34 - 0.071 0.25
10 0.43 0.32 0.081 0.31
16 0.51 0.38 0.088 0.36
25 0.49 0.38 0.089 0.41
35 0.57 0.44 0.096 0.47
50 0.58 0.46 0.098 0.50
70 0.63 0.51 0.100 0.53
95 0.73 0.59 0.110 0.61
120 0.74 0.61 0.110 0.63
150 0.73 0.61 0.110 0.64
185 0.69 0.59 0.110 0.65
240 0.74 0.64 0.110 0.66
300 0.80 0.69 0.120 0.67
400 0.83 0.70 0.120 0.67
500 0.83 0.71 0.120 0.69
630 0.87 0.75 0.110 0.73
800 0.92 0.78 - -
1000 0.94 0.81 - -

REACTANCE APPROXIMATE REACTANCE AT 50 HZ (Ohm/Km) 1.1 KV XLPE CABLES.

Nominal Area of Single Core Multi Core
Conductor Unarmoured Armoured
1.5 0.155 - 0.107
2.5 0.142 - 0.0985
4 0.132 - 0.0927
6 0.123 - 0.0884
10 0.114 0.134 0.0837
16 0.108 0.125 0.0808
25 0.103 0.120 0.0805
35 0.0986 0.114 0.0783
50 0.0937 0.108 0.0750
70 0.0900 0.102 0.0740
95 0.0865 0.100 0.0724
120 0.0841 0.0968 0.0712
150 0.0839 0.0941 0.0716
185 0.0836 0.0932 0.0718
240 0.0813 0.0900 0.0710
300 0.0795 0.0881 0.0705
400 0.0787 0.0873 0.0704
500 0.0779 0.0859 0.0702
630 0.0785 0.0843 0.0698
800 0.0755 0.0826 -
1000 0.0752 0.0825 -

6
 ©

Technical Data
AN ISO 9001:2000 COMPANY

CONDUCTOR TECHNICAL INFORMATION FOR SINGLE CORE AND MULTICORE CABLES CONFORMING TO
IS-8130/1984 (STRANDED - CLASS-2) COPPER & ALUMINIUM CONDUCTORS.
Nominal Minimum no. of wires Max D.C. Resistance at 20°C A. C. Resistance at 90°C
Size of
Non Compacted Compacted Plain Copper Aluminium Plain Copper Aluminium
Conductor
Round/ Shaped
Sq.mm CU. ALU. CU. ALU. Ohm/Km Ohm/Km Ohm/Km Ohm/Km
1.5* 3 3 - - 12.1 18.10 15.50 23.17
2.5* 3 3 - - 7.41 12.10 9.48 15.50
4* 7 3 - - 4.61 7.41 5.90 9.48
6* 7 3 - - 3.08 4.61 3.94 5.90
10* 7 7 6 - 1.83 3.08 2.34 3.94
16 7 7 6 6 1.15 1.91 1.47 2.44
25 7 7 6 6 0.727 1.20 0.930 1.54
35 7 7 6 6 0.524 0.868 0.671 1.11
50 19 19 6 6 0.387 0.641 0.495 0.82
70 19 19 12 12 0.268 0.443 0.343 0.567
95 19 19 15 15 0.193 0.320 0.247 0.410
120 37 37 18 15 0.153 0.253 0.196 0.324
150 37 37 18 15 0.124 0.206 0.159 0.264
185 37 37 30 30 0.0991 0.164 0.127 0.210
240 61 37 34 30 0.0754 0.125 0.0965 0.160
300 61 61 34 30 0.0601 0.100 0.0769 0.128
400 61 61 53 53 0.0469 0.0778 0.0602 0.100
500 61 61 53 53 0.0366 0.0605 0.0468 0.0774
630 91 91 53 53 0.0283 0.0469 0.0362 0.0600
800 91 91 53 53 0.0221 0.0367 0.0283 0.0470
1000 91 91 53 53 0.0176 0.0291 0.0225 0.0372
* These sizes can be manufactured with solid conductor having single strand

POLYCAB RECOMDATIONS FOR CURRENT RATINGS

1. The values given in the table are valid for on circuit in a three phase system under conditions
specified. For grouping cables rating factors must be used.
2. The current carrying capacities mentioned in POLYCAB technical data are intended as a guide, to
assist operating engineers in selecting cables for safety and reliability.
3. Basic assumptions and condition of installation:
* Ambient ground Temperature : 30° C
* Ambient air Temperature: 40° C
* Depth of Cable Burial : 1.0 m
* Thermal resistivity of soil : 150° C. Cm/W
4. Single Core Cables are installed as indicated in the table, spacing between cables in flat formation is as
indicated.
5. For 3 and 4 core cables, it is usual to assume the same current carrying capacity for 4 core cables as for 3
core cables. Our calculated values are based actually on 3 core cables. These values are suitable with
enough accuracy also for 4 cables in most cases. Only for large 4 core cables in air the values are too
conservative, due to the large cable surface and consequent high heat dissipation factor.
6. To obtain the maximum current carrying capacity of a cable operating at different conditions from the
standard. Various rating factors are to be multiplied as follows:
Ia = K Is (in Amperes) Where
Ia = Current Rating at actual Operating Conditions (amperes)

7
 Is = Current Rating at Standard Operating Conditions
(amperes) K = Rating Factor as applicable

6
8

cables
Current carrying capacity of
Weight, Dimension data &
TABLE-1 “POLYCAB” SINGLE CORE ALUMINIUM CONDUCTOR, XLPE INSULATED,
UNARMOURED & ARMOURED CABLE CONFORMING TO IS 7098 PART-1/1988

650/1100 VOLTS WEIGHT & DIMENSIONS

Nomin Form of Nomin Mini- Unarmoured Cable Nomina Formed Wire/ Strip Armoured Cable Round Wire Armoured Cable Curren Rating *Norm
al Size Conductor al mum l t . al
of Circular Thick- Thick Nomin Approx Approx Thicknes Nomina Mini- Approx Approx Nomin Mini- Approx Approx In In Air Deliver
Conduc ness - al . . s of l mum . . al mum . . Ground. y
- tor of ness Thick- Overal Weigh XLPE Dimen Thick Overal Weigh Dimen Thick Overal Weigh Length
XLPE of ness l t of insula- - sion - l t of - sion - l t of .
Insula PVC of Diam- Cable. tion for of ness Diam- Cable. of Alu- ness Diam- Cable.
- tion Inner PVC eter Armoure Alumin of eter miniu of eter
for Sheat Outer of d Cable - ium PVC of m PVC of
U/A h Sheat Cable. Flat Outer Cable. Round Outer Cable.
h Strip. Sheat Wire. Sheat
h h
Sq.mm. mm mm mm mm Kgs./Km mm mm mm mm Kgs./Km mm mm mm Kgs./Km Amps. Amps. Mtrs.
4 Solid 0.7 -NA- 1.8 7.5 60 - - - - - - - - - 36 31 1000
4 Stranded 0.7 -NA- 1.8 8.0 65 - - - - - - - - - 36 31 1000
6 Solid 0.7 -NA- 1.8 8.0 70 - - - - - - - - - 44 39 1000
6 Stranded 0.7 -NA- 1.8 8.5 75 - - - - - - - - - 44 39 1000
10 Solid 0.7 -NA- 1.8 9.0 80 1.0 - - - - - - - - 59 53 1000
10 Stranded 0.7 -NA- 1.8 9.5 90 1.0 - - - - - - - - 59 53 1000
16 Stranded 0.7 -NA- 1.8 10.0 115 1.0 - - - - 1.4 1.24 13.0 220 76 73 1000
25 --do-- 0.9 -NA- 1.8 12.0 155 1.2 - - - - 1.4 1.24 14.0 260 96 98 1000
35 --do-- 0.9 -NA- 1.8 13.0 180 1.2 - - - - 1.4 1.24 15.0 310 114 121 1000
50 --do-- 1.0 -NA- 1.8 14.0 240 1.3 - - - - 1.4 1.24 17.0 380 135 150 1000
70 --do-- 1.1 -NA- 1.8 16.0 310 1.4 - - - - 1.4 1.24 19.0 480 166 187 1000
95 --do-- 1.1 -NA- 1.8 17.5 385 1.4 4x 1.40 21.0 560 1.6 1.40 22.0 640 198 230 1000
0.80
120 --do-- 1.2 -NA- 1.8 19.0 470 1.5 4 x 0.80 1.40 22.0 660 1.6 1.40 23.5 745 225 268 1000
150 --do-- 1.4 -NA- 2.0 21.5 600 1.7 4x 1.40 23.0 750 1.6 1.40 24.5 850 253 309 1000
0.80
185 --do-- 1.6 -NA- 2.0 23.5 710 1.9 4 x 0.80 1.40 25.0 900 1.6 1.40 26.5 1000 286 360 1000
240 --do-- 1.7 -NA- 2.0 26.0 900 2.0 4x 1.40 27.5 1100 1.6 1.40 29.0 1215 332 433 1000
0.80
300 --do-- 1.8 -NA- 2.0 28.5 1075 2.1 4 x 0.80 1.56 30.0 1350 1.6 1.56 31.5 1475 376 501 1000
400 --do-- 2.0 -NA- 2.2 33.0 1385 2.4 4x 1.56 34.0 1725 2.0 1.56 36.5 1925 431 596 500
0.80
500 --do-- 2.2 -NA- 2.2 36.0 1650 2.6 4 x 0.80 1.56 37.5 2090 2.0 1.56 39.5 2300 490 693 500
630 --do-- 2.4 -NA- 2.2 40.0 2100 2.8 4x 1.72 40.5 2525 2.0 1.72 43.0 2800 557 814 500
0.80
 800 --do-- 2.6 -NA- 2.4 46.0 2730 3.1 4 x 0.80 1.72 46.5 3150 2.0 1.88 49.5 3450 600 890 500
1000 --do-- 2.8 -NA- 2.6 52.0 3350 3.3 4x 1.88 54.0 3963 2.5 2.04 58.0 4475 650 1050 500
0.80
The above data is approximate and subject to manufacturing tolerance.
* Delivery Length tolerance is ± 5 %. Length more than normal as per customer request.
 cables
Current carrying capacity of
Weight, Dimension data &
TABLE-2 “POLYCAB” SINGLE CORE COPPER CONDUCTOR, XLPE INSULATED,
UNARMOURED & ARMOURED CABLE CONFORMING TO IS 7098 PART-1/1988

650/1100 VOLTS WEIGHT & DIMENSIONS

Nominal Form of Nominal Mini- Unarmoured Cable Nominal Formed Wire/ Strip Armoured Cable Round Wire Armoured Cable Current Rating. *Norm
Size Conducto Thick- mum Nominal Approx. Approx. Thick- Nomina Mini- Approx. Approx. Nominal Mini- Approx. Approx. In In Air al
of r ness Thick Thick- Overal Weigh ness l mum Overal Weigh Dimensio mum Overal Weigh Ground. Deliver
Conduc Circular of - ness l t of of Dimen Thick l t of n of Alu- Thick l t of y
- tor XLPE ness of Diam- Cable. XLPE - sion - Diam- Cable. minium - Diam- Cable. Length
Insula- tion of PVC eter insula- tion of ness eter Round ness eter .
for PVC Outer of for Ar- Alumin of of Wire. of of
U/A Inner Sheat Cable. moure - ium PVC Cable. PVC Cable.
Sheat h d Flat Outer Outer
h Cable Strip. Sheat Sheat
h h
Sq.mm. mm mm mm mm Kgs./Km mm mm mm mm Kgs./Km mm mm mm Kgs./Km Amps. Amps. Mtrs.
4 Solid 0.7 -NA- 1.8 7.5 91 - - - - - - - - - 47 42 1000
4 Stranded 0.7 -NA- 1.8 8.0 95 - - - - - - - - - 47 42 1000
6 Solid 0.7 -NA- 1.8 8.0 115 - - - - - - - - - 59 53 1000
6 Stranded 0.7 -NA- 1.8 8.5 125 - - - - - - - - - 59 53 1000
10 Stranded 0.7 -NA- 1.8 9.5 170 1.0 - - - - 1.4 1.24 12.0 245 78 72 1000
16 Stranded 0.7 -NA- 1.8 10.0 220 1.0 - - - - 1.4 1.24 13.0 315 102 98 1000
25 Stranded 0.9 -NA- 1.8 12.0 325 1.2 - - - - 1.4 1.24 14.0 415 132 132 1000
35 Stranded 0.9 -NA- 1.8 13.0 420 1.2 - - - - 1.4 1.24 16.0 525 156 156 1000
50 Stranded 1.0 -NA- 1.8 14.0 550 1.3 - - - - 1.4 1.24 17.0 690 186 198 1000
70 Stranded 1.1 -NA- 1.8 16.0 750 1.4 - - - - 1.4 1.24 19.0 910 228 246 1000
95 Stranded 1.1 -NA- 1.8 17.5 1010 1.4 4 x 0.80 1.40 21.0 1150 1.6 1.40 22.0 1325 264 294 1000
120 Stranded 1.2 -NA- 1.8 19.0 1250 1.5 4 x 0.80 1.40 22.0 1400 1.6 1.40 23.5 1485 300 336 1000
150 Stranded 1.4 -NA- 2.0 21.5 1550 1.7 4 x 0.80 1.40 23.0 1680 1.6 1.40 24.5 1780 336 384 1000
185 Stranded 1.6 -NA- 2.0 23.5 1900 1.9 4 x 0.80 1.40 25.0 2040 1.6 1.40 26.5 2140 366 444 1000
240 Stranded 1.7 -NA- 2.0 26.0 2450 2.0 4 x 0.80 1.40 27.5 2580 1.6 1.40 29.0 2700 414 510 1000
300 Stranded 1.8 -NA- 2.0 28.5 3050 2.1 4 x 0.80 1.56 30.0 3200 1.6 1.56 31.5 3325 450 570 500
400 Stranded 2.0 -NA- 2.2 33.0 4035 2.4 4 x 0.80 1.56 34.0 4200 2.0 1.56 36.5 4400 480 660 500
500 Stranded 2.2 -NA- 2.2 36.0 5020 2.6 4 x 0.80 1.56 37.5 5180 2.0 1.56 39.5 5400 564 708 500
630 Stranded 2.4 -NA- 2.2 40.0 6250 2.8 4 x 0.80 1.72 40.5 6425 2.0 1.72 43.0 6700 570 825 500
800 Stranded 2.6 -NA- 2.4 46.0 7900 3.1 4 x 0.80 1.72 46.5 8100 2.0 1.88 49.5 8400 660 945 500

COMPANY
AN ISO 9001:2000
1000 Stranded 2.8 NA- 2.6 52.0 9850 3.3 x 0.80 1.88 54.0 10150 2.5 2.04 58.0 10660 723 1063 500
The above data is approximate and subject to manufacturing tolerance.
* Delivery Length tolerance is ± 5 %. Length more than normal as per customer request.
9

©
1

cables
Current carrying capacity of
Weight, Dimension data &
TABLE-3 “POLYCAB” TWO CORE ALUMINIUM CONDUCTOR, XLPE INSULATED,
UNARMOURED & ARMOURED CABLE CONFORMING TO IS 7098 PART-1/1988

650/1100 VOLTS WEIGHT AND DIMENSIONS

Nominal Form of Nominal Mini- Unarmoured Cable Formed Wire/ Strip Armoured Cable Round Wire Armoured Cable Current Rating. *Norm
Size Conductor Thick- mum Nominal Approx Approx Nomin Mini- Approx Approx Nomin Mini- Approx Approx In In Air al
of Circular ness Thick Thick- . . al mum . . al mum . . Ground. Deliver
Conduc Shaped of - ness Overall Weight Dimen Thick Overall Weight Dimen Thick Overall Weight y
- tor XLPE ness of Diamete of - sion - Diamete of - sion - Diamete of Length
Insula- tion of PVC r of Cable. of GI ness r of Cable. of ness r of Cable. .
PVC Outer Cable. Flat of Cable. GI of Cable.
Inner Sheat Strip. PVC Roun PVC
Sheat h Outer d Outer
h Sheat Wire. Sheat
h h
Sq.mm. mm mm mm mm mm Kgs./Km mm mm mm Kgs./Km mm mm mm Kgs./Km Amps. Amps. Mtrs.
4 Solid 0.7 0.3 1.8 12.5 140 -NA- -NA- -NA- -NA- 1.40 1.24 14.5 400 40 34 1000
4 Stranded 0.7 0.3 1.8 13.0 150 -NA- -NA- -NA- -NA- 1.40 1.24 15.5 430 40 34 1000
6 Solid 0.7 0.3 1.8 13.5 170 -NA- -NA- -NA- -NA- 1.40 1.24 15.5 470 50 44 1000
6 Stranded 0.7 0.3 1.8 14.0 180 -NA- -NA- -NA- -NA- 1.40 1.24 16.5 485 50 44 1000
10 Solid 0.7 0.3 1.8 15.0 205 -NA- -NA- -NA- -NA- 1.40 1.24 17.0 545 69 59 1000
10 Stranded 0.7 0.3 1.8 16.0 225 -NA- -NA- -NA- -NA- 1.40 1.24 18.0 565 69 59 1000
16 Stranded 0.7 0.3 1.8 14.0 225 -NA- -NA- -NA- -NA- 1.40 1.40 17.0 570 88 74 1000
25 Stranded 0.9 0.3 2.0 17.0 330 4 x 0.8 1.40 18.5 600 1.60 1.40 20.0 790 112 98 1000
35 Stranded 0.9 0.3 2.0 19.0 410 -do- 1.40 20.0 690 1.60 1.40 22.0 910 138 124 1000
50 Stranded 1.0 0.3 2.0 21.0 510 -do- 1.40 22.5 820 1.60 1.40 24.0 1050 169 156 1000
70 Stranded 1.1 0.3 2.0 23.0 675 -do- 1.56 25.5 1050 1.60 1.56 27.0 1325 200 188 1000
95 Stranded 1.1 0.4 2.2 26.5 900 -do- 1.56 28.0 1300 2.00 1.56 30.5 1750 238 231 1000
120 Stranded 1.2 0.4 2.2 28.5 1050 -do- 1.56 30.5 1500 2.00 1.56 33.0 2000 262 262 500
150 Stranded 1.4 0.4 2.2 32.0 1215 -do- 1.72 34.0 1750 2.00 1.72 36.0 2250 300 300 500
185 Stranded 1.6 0.5 2.4 35.5 1510 -do- 1.72 37.0 2200 2.00 1.88 40.0 2750 344 344 500
240 Stranded 1.7 0.5 2.6 39.5 1900 -do- 1.88 41.0 2600 2.50 2.04 45.0 3700 400 406 500
300 Stranded 1.8 0.6 2.8 43.5 2360 -do- 2.04 45.5 3200 2.50 2.20 49.0 4400 444 456 500

The above data is approximate and subject to manufacturing tolerance.

* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.
400 Stranded 2.0 0.6 3.0 49.0 3100 -do- 2.36 51.0 4000 2.50 2.36 54.4 5300 481 525 500
500 Stranded 2.2 0.7 3.4 55.5 4000 -do- 2.52 56.5 5000 3.15 2.68 61.5 7000 523 678 500
630 Stranded 2.4 0.7 3.6 61.5 5000 -do- 2.68 62.5 6050 3.15 2.84 67.5 8560 592 786 500
 cables
Current carrying capacity of
Weight, Dimension data &
TABLE-4 “POLYCAB” TWO CORE COPPER CONDUCTOR, XLPE INSULATED,
UNARMOURED & ARMOURED CABLE CONFORMING TO IS 7098 PART-1/1988

650 / 1100 VOLTS WEIGHT AND DIMENSIONS

Nomin Form of Nomin Mini- Unarmoured Cable Formed Wire/ Strip Armoured Cable Round Wire Armoured Cable Current Rating. *
al Size Conductor al mum Nomin Approx Approx Nomin Minimu Approx Approx Nomin Minimu Approx Approx In In Air Normal
of Circular Thick- Thick al . . al m . . al m . . Ground. Deliver
Conduc Shaped ness - Thick- Overall Weight Dimen Thick- Overall Weight Dimen Thick- Overall Weight y
- tor of ness ness Diamete of - sion ness of Diamete of - sion ness of Diamete of Length
XLPE of of r of Cable. of GI PVC r of Cable. of PVC r of Cable. .
Insula- PVC PVC Cable. Flat Outer Cable. GI Outer Cable.
tion Inner Outer Strip. Sheath Roun Sheath
Sheat Sheat d
h h Wire.
Sq.mm. mm mm mm mm mm Kgs./Km mm mm mm Kgs./Km mm mm mm Kgs./Km Amps. Amps. Mtrs.
4 Solid 0.7 0.3 1.8 12.5 165 -NA- -NA- -NA- -NA- 1.4 1.24 14.5 480 51 44 1000
4 Stranded 0.7 0.3 1.8 13.0 175 -NA- -NA- -NA- -NA- 1.4 1.24 15.5 525 51 44 1000
6 Solid 0.7 0.3 1.8 13.5 210 -NA- -NA- -NA- -NA- 1.4 1.24 15.5 564 63 56 1000
6 Stranded 0.7 0.3 1.8 14.0 225 -NA- -NA- -NA- -NA- 1.4 1.24 16.5 610 63 56 1000
10 Stranded 0.7 0.3 1.8 16.0 300 -NA- -NA- -NA- -NA- 1.4 1.24 18.0 740 88 75 1000
16 Stranded 0.7 0.3 1.8 14.0 425 -NA- -NA- -NA- -NA- 1.4 1.40 17.0 770 113 98 1000
25 Stranded 0.9 0.3 2.0 17.0 640 4 x 0.8 1.40 18.5 910 1.6 1.40 20.0 1100 144 131 1000
35 Stranded 0.9 0.3 2.0 19.0 840 -do- 1.40 20.0 1025 1.6 1.40 22.0 1350 175 150 1000
50 Stranded 1.0 0.3 2.0 21.0 1120 -do- 1.40 22.5 1435 1.6 1.40 24.0 1670 206 194 1000
70 Stranded 1.1 0.3 2.0 23.0 1540 -do- 1.56 25.5 1910 1.6 1.56 27.0 2200 256 244 1000
95 Stranded 1.1 0.4 2.2 26.5 2075 -do- 1.56 28.0 2475 2.0 1.56 30.5 2925 300 288 500
120 Stranded 1.2 0.4 2.2 28.5 2535 -do- 1.56 30.5 2985 2.0 1.56 33.0 3485 344 331 500
150 Stranded 1.4 0.4 2.2 32.0 3070 -do- 1.72 34.0 3600 2.0 1.72 36.0 4100 388 381 500
185 Stranded 1.6 0.5 2.4 35.5 3800 -do- 1.72 37.0 4490 2.0 1.88 40.0 5040 438 438 500
240 Stranded 1.7 0.5 2.6 39.5 4870 -do- 1.88 41.0 5575 2.5 2.04 45.0 7370 506 512 500
300 Stranded 1.8 0.6 2.8 43.5 6075 -do- 2.04 45.5 6910 2.5 2.20 49.0 9010 562 581 500
400 Stranded 2.0 0.6 3.0 49.0 8050 -do- 2.36 51.0 8950 2.5 2.36 54.4 10250 612 662 500
The above data is approximate and subject to manufacturing tolerance.
* Delivery Length tolerance is ± 5 %. Length more than normal as per customer request.
The above data is approximate and subject to manufacturing tolerance.
* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.

COMPANY
AN ISO 9001:2000
1

©
1

cables
Current carrying capacity of
Weight, Dimension data &
TABLE-5 “POLYCAB” THREE CORE ALUMINIUM CONDUCTOR, XLPE INSULATED,
UNARMOURED & ARMOURED CABLE CONFORMING TO IS 7098 PART-1/1988

650/1100 VOLTS WEIGHT AND DIMENSIONS

Nomin Form of Nomin Mini- Unarmoured Cable Formed Wire/ Strip Armoured Cable Round Wire Armoured Cable Current Rating. *Norm
al Size Conductor al mum Nomin Approx Approx Nomin Minimu Approx Approx Nomin Mini- Approx Approx In In Air al
of Circular Thick- Thick al . . al m . . al mum . . Ground. Deliver
Conduc Shaped ness - Thick- Overall Weight Dimen Thick- Overall Weight Dimen Thick Overall Weight y
- tor of ness ness Diamete of - sion ness of Diamete of - sion - Diamete of Length
XLPE of of r of Cable. of GI PVC r of Cable. of ness r of Cable. .
Insula- PVC PVC Cable. Flat Outer Cable. GI of Cable.
tion Inner Outer Strip. Sheath Roun PVC
Sheat Sheat d Outer
h h Wire. Sheat
h
Sq.mm. mm mm mm mm mm Kgs./Km mm mm mm Kgs./Km mm mm mm Kgs./Km Amps. Amps. Mtrs.
4 Solid 0.7 0.3 1.8 14.0 140 -NA- -NA- -NA- -NA- 1.40 1.24 15.0 460 34 31 1000
4 Strande 0.7 0.3 1.8 15.5 160 -NA- -NA- -NA- -NA- 1.40 1.24 16.0 510 34 31 1000
6 d Solid 0.7 0.3 1.8 15.5 170 -NA- -NA- -NA- -NA- 1.40 1.24 16.0 530 43 50 1000
6 Strande 0.7 0.3 1.8 16.0 190 -NA- -NA- -NA- -NA- 1.40 1.24 17.0 580 43 50 1000
10 d Solid 0.7 0.3 1.8 17.0 220 -NA- -NA- -NA- -NA- 1.40 1.24 18.0 640 57 67 1000
10 Stranded 0.7 0.3 1.8 18.0 230 -NA- -NA- -NA- -NA- 1.40 1.24 19.0 680 57 67 1000
16 Stranded 0.7 0.3 1.8 18.0 310 4 x 0.8 1.24 18.5 530 1.60 1.40 21.0 750 73 70 1000
25 Stranded 0.9 0.3 2.0 20.0 460 -do- 1.40 20.5 770 1.60 1.40 23.0 990 94 96 1000
35 Stranded 0.9 0.3 2.0 21.5 575 -do- 1.40 23.0 900 1.60 1.40 25.0 1150 113 117 1000
50 Stranded 1.0 0.3 2.0 24.5 700 -do- 1.40 25.5 1100 1.60 1.56 27.5 1400 133 142 1000
70 Stranded 1.1 0.4 2.2 29.0 990 -do- 1.56 30.0 1425 2.00 1.56 32.0 1950 164 179 500
95 Stranded 1.1 0.4 2.2 32.5 1250 -do- 1.56 33.5 1735 2.00 1.56 37.5 2300 196 221 500
120 Stranded 1.2 0.4 2.2 34.5 1525 -do- 1.56 35.5 2050 2.00 1.72 39.5 2700 223 257 500
150 Stranded 1.4 0.5 2.4 38.5 1900 -do- 1.72 40.5 2100 2.00 1.88 43.5 3200 249 292 500
185 Stranded 1.6 0.5 2.6 43.5 2380 -do- 1.88 44.5 2500 2.50 2.04 48.5 4200 282 337 500
240 Stranded 1.7 0.6 2.8 48.5 3000 -do- 2.04 49.0 3700 2.50 2.20 53.0 5100 326 399 500
300 Stranded 1.8 0.6 3.0 51.5 3750 -do- 2.20 53.0 4500 2.50 2.36 57.5 5900 367 455 500
400 Stranded 2.0 0.7 3.2 59.5 4760 -do- 2.52 58.5 5700 3.15 2.68 65.0 7900 418 530 500
 500 Stranded 2.2 0.7 3.6 66.0 6000 -do- 2.68 67.0 6900 3.15 2.84 73.0 9550 470 612 250
630 Stranded 2.4 0.7 3.8 72.0 7550 -do- 2.84 73.0 8700 4.00 3.00 78.0 12500 529 707 250

The above data is approximate and subject to manufacturing tolerance.

* Delivery Length tolerance is ± 5 %. Length more than normal as per
customer request.
 cables
Current carrying capacity of
Weight, Dimension data &
TABLE-6 “POLYCAB” THREE CORE COPPER CONDUCTOR, XLPE INSULATED,
UNARMOURED & ARMOURED CABLE CONFORMING TO IS 7098 PART-1/1988

650/1100 VOLTS WEIGHT AND DIMENSIONS

Nomin Form of Nomin Mini- Unarmoured Cable Formed Wire/ Strip Armoured Cable Round Wire Armoured Cable Current Rating. *Norm
al Size Conductor al mum Nomin Approx Approx Nomin Minimu Approx Approx Nomin Mini- Approx Approx In In Air al
of Circular Thick- Thick al . . al m . . al mum . . Ground. Deliver
Conduc Shaped ness - Thick- Overall Weight Dimen Thick- Overall Weight Dimen Thick Overall Weight y
- tor of ness ness Diamete of - sion ness of Diamete of - sion - Diamete of Length
XLPE of of r of Cable. of GI PVC r of Cable. of ness r of Cable. .
Insula PVC PVC Cable. Flat Outer Cable. GI of Cable.
- tion Inner Outer Strip. Sheath Roun PVC
Sheat Sheat d Outer
h h Wire. Sheat
h
Sq.mm. mm mm mm mm mm Kgs./Km mm mm mm Kgs./Km mm mm mm Kgs./Km Amps. Amps. Mtrs.
4 Solid 0.7 0.3 1.8 14.0 210 -NA- -NA- -NA- -NA- 1.40 1.24 15.0 530 43 36 1000
4 Stranded 0.7 0.3 1.8 15.5 235 -NA- -NA- -NA- -NA- 1.40 1.24 16.0 580 43 36 1000
6 Solid 0.7 0.3 1.8 15.5 280 -NA- -NA- -NA- -NA- 1.40 1.24 16.0 640 54 47 1000
6 Stranded 0.7 0.3 1.8 16.0 300 -NA- -NA- -NA- -NA- 1.40 1.24 17.0 680 54 47 1000
10 Stranded 0.7 0.3 1.8 18.0 415 -NA- -NA- -NA- -NA- 1.40 1.24 19.0 865 72 62 1000
16 Stranded 0.7 0.3 1.8 18.0 425 4 x 0.8 1.24 18.5 825 1.60 1.40 21.0 1040 92 79 1000
25 Stranded 0.9 0.3 2.0 20.0 920 -do- 1.40 20.5 1235 1.60 1.40 23.0 1450 119 108 1000
35 Stranded 0.9 0.3 2.0 21.5 1225 -do- 1.40 23.0 1550 1.60 1.40 25.0 1800 144 132 1000
50 Stranded 1.0 0.3 2.0 24.5 1620 -do- 1.40 25.5 2020 1.60 1.56 27.5 2320 174 162 1000
70 Stranded 1.1 0.4 2.2 29.0 2290 -do- 1.56 30.0 2720 2.00 1.56 32.0 3250 210 198 500
95 Stranded 1.1 0.4 2.2 32.5 3010 -do- 1.56 33.5 3500 2.00 1.56 37.5 4060 252 240 500
120 Stranded 1.2 0.4 2.2 34.5 3750 -do- 1.56 35.5 4320 2.00 1.72 39.5 4920 288 276 500
150 Stranded 1.4 0.5 2.4 38.5 4760 -do- 1.72 40.5 5280 2.00 1.88 43.5 5980 324 318 500
185 Stranded 1.6 0.5 2.6 43.5 5810 -do- 1.88 44.5 6385 2.50 2.04 48.5 7630 360 366 500
240 Stranded 1.7 0.6 2.8 48.5 7450 -do- 2.04 49.0 8150 2.50 2.20 53.0 9550 414 426 500
300 Stranded 1.8 0.6 3.0 51.5 9310 -do- 2.20 53.0 10060 2.50 2.36 57.5 11460 462 480 500
400 Stranded 2.0 0.7 3.2 59.5 12200 -do- 2.52 58.5 13125 3.15 2.68 65.0 15320 510 546 250
The above data is approximate and subject to manufacturing tolerance.
* Delivery Length tolerance is ± 5 %. Length more than normal as per customer request.

COMPANY
AN ISO 9001:2000
1

©
1

cables
Current carrying capacity of
Weight, Dimension data &
TABLE-7 “POLYCAB” THREE AND HALF CORE ALUMINIUM CONDUCTOR, XLPE INSULATED
UNARMOURED & ARMOURED CABLE CONFORMING TO IS 7098 PART-1/1988

650/1100 VOLTS WEIGHT AND DIMENSIONS

Nomin Form of Nominal Mini- Unarmoured Cable Formed Wire/ Strip Armoured Cable Round Wire Armoured Cable Curren Rating *Norm
al Size Conductor Thickness of mu t . al
of Shaped XLPE Insulation m Nomin Approx Approx Nomin Mini- Approx Approx Nomin Mini- Approx Approx In In Air Deliver
Conduc Main / Neutral Thick al . . al mum . . al mum . . Groun y
- tors - Thick- Overal Weigh Dimen Thick Overal Weigh Dimen Thick Overal Weigh d Length
ness ness l t of - sion - l t of - sion - l t of .
of of Diam- Cable. of GI ness Diam- Cable. of ness Diam- Cable.
PVC PVC eter Flat of eter GI of eter
Inner Outer of Strip. PVC of Roun PVC of
Sheat Sheat Cable. Outer Cable. d Outer Cable.
h h Sheat Wire. Sheat
h h
Sq.mm. mm mm mm mm mm mm Kgs./Km mm mm mm Kgs./Km mm mm mm Kgs./Km Amps. Amps. Mtrs.
25/16 Stranded 0.9 0.7 0.3 2.0 22.0 525 4 x 0.80 1.40 23.0 850 1.60 1.40 25.5 1050 94 96 1000
35/16 Stranded 0.9 0.7 0.3 2.0 24.0 625 -do- 1.40 25.0 980 1.60 1.40 26.5 1200 113 117 1000
50/25 Stranded 1.0 0.9 0.3 2.0 27.5 800 -do- 1.40 28.0 1240 1.60 1.56 29.5 1500 133 142 1000
70/35 Stranded 1.1 0.9 0.4 2.2 31.0 1100 -do- 1.56 32.0 1600 2.00 1.56 34.0 2050 164 179 500
95/50 Stranded 1.1 1.0 0.4 2.2 35.0 1400 -do- 1.56 36.0 1900 2.00 1.56 38.0 2450 196 221 500
120/70 Stranded 1.2 1.1 0.4 2.2 37.5 1650 -do- 1.72 39.0 2300 2.00 1.72 41.0 2800 223 257 500
150/70 Stranded 1.4 1.1 0.5 2.4 41.0 2000 -do- 1.72 42.0 2650 2.00 1.88 45.0 3350 249 292 500
185/95 Stranded 1.6 1.1 0.5 2.6 46.5 2550 -do- 1.88 47.5 3250 2.50 2.04 50.0 4500 282 337 500
240/120 Stranded 1.7 1.2 0.6 2.8 52.5 3200 -do- 2.04 53.5 4100 2.50 2.20 56.0 5450 326 399 500
300/150 Stranded 1.8 1.4 0.6 3.0 56.0 4000 -do- 2.20 57.0 4950 2.50 2.36 61.0 6400 367 455 500
400/185 Stranded 2.0 1.6 0.7 3.4 64.0 5250 -do- 2.52 65.0 6150 3.15 2.68 70.0 8300 418 530 500
500/240 Stranded 2.2 1.7 0.7 3.6 72.5 6500 -do- 2.68 73.5 7600 3.15 2.84 77.0 10000 470 612 250
The above data is approximate and subject to manufacturing tolerance.
* Delivery Length tolerance is ± 5 %. Length more than normal as per customer request.
 cables
Current carrying capacity of
Weight, Dimension data &
TABLE-8 “POLYCAB” THREE AND HALF CORE COPPER CONDUCTOR, XLPE INSULATED
UNARMOURED & ARMOURED CABLE CONFORMING TO IS 7098 PART-1/1988

650/1100 VOLTS WEIGHT AND DIMENSIONS

Nominal Form of Nominal Mini- Unarmoured Cable Formed Wire/ Strip Armoured Cable Round Wire Armoured Cable Current Rating. *Norm
Size Conductor Thickness of mu Nominal Approx. Approx. Nomin Mini- Approx. Approx. Nomin Mini- Approx. Approx. In In Air al
of Shaped XLPE m Thick- Overal Weigh al mum Overal Weigh al mum Overal Weigh Groun Deliver
Conduc Insulation Thick ness l t of Dimen Thick l t of Dimen Thick l t of d y
- tors Main / - of Diam- Cable. - sion - Diam- Cable. - sion - Diam- Cable. Length
Neutral ness PVC eter of GI ness eter of ness eter .
PVC Inner Outer of Flat of of GI of of
Sheath Sheat Cable. Strip. PVC Cable. Roun PVC Cable.
h Outer d Outer
Sheat Wire. Sheat
h h
Sq.mm. mm mm mm mm mm mm Kgs./Km mm mm mm Kgs./Km mm mm mm Kgs./Km Amps. Amps. Mtrs.
25/16 Stranded 0.9 0.7 0.3 2.0 22.0 1080 4 x 0.80 1.40 23.0 1410 1.60 1.40 24.0 1610 119 108 1000
35/16Stranded 0.9 0.7 0.3 2.0 24.0 1370 -do- 1.40 25.0 1725 1.60 1.40 26.0 1950 144 132 1000
50/25 Stranded 1.0 0.9 0.3 2.0 27.5 1875 -do- 1.40 28.0 2325 1.60 1.56 29.0 2580 174 162 1000
70/35Stranded 1.1 0.9 0.4 2.2 31.0 2620 -do- 1.56 32.0 3110 2.00 1.56 34.0 3560 210 198 500
95/50 Stranded 1.1 1.0 0.4 2.2 35.0 3475 -do- 1.56 36.0 8975 2.00 1.56 37.5 4525 252 240 500
120/70
Stranded 1.2 1.1 0.4 2.2 39.0 4315 -do- 1.72 40.0 4960 2.00 1.72 41.0 5460 288 276 500
150/70 Stranded 1.4 1.1 0.5 2.4 43.0 5220 -do- 1.72 44.0 5870 2.00 1.88 45.0 6570 324 318 500
185/95
Stranded 1.6 1.1 0.5 2.6 48.0 6575 -do- 1.88 50.0 7275 2.50 2.04 50.0 8520 360 366 500
240/120Stranded 1.7 1.2 0.6 2.8 54.0 8400 -do- 2.04 55.0 9300 2.50 2.20 56.0 10650 414 426 500
300/150
Stranded 1.8 1.4 0.6 3.0 57.0 10500 -do- 2.20 58.0 11500 2.50 2.36 61.0 12400 462 480 500
400/185 Stranded 2.0 1.6 0.7 3.4 65.0 13820 do- 2.52 66.0 14720 3.15 2.68 70.0 16875 510 546 250
The above data is approximate and subject to manufacturing tolerance.
* Delivery Length tolerance is ± 5 %. Length more than normal as per customer request.

COMPANY
AN ISO 9001:2000
©
1
1

cables
Current carrying capacity of
Weight, Dimension data &
TABLE-9 “POLYCAB” FOUR CORE ALUMINIUM CONDUCTOR, XLPE INSULATED,
UNARMOURED & ARMOURED CABLE CONFORMING TO IS 7098 PART-1/1988

650/1100 VOLTS WEIGHT AND DIMENSIONS

Nomin Form of Nomin Mini- Unarmoured Cable Formed Wire/ Strip Armoured Cable Round Wire Armoured Cable Curren Rating *Norm
al Size Conductor al mum t . al
of Circular Thick- Thick Nomin Approx Approx Nomin Mini- Approx Approx Nomin Mini- Approx Approx In In Air Deliver
Conduc Shaped ness - al . . al mum . . al mum . . Ground. y
- tor of ness Thick- Overall Weight Dimen Thick Overall Weight Dimen Thick Overall Weight Length
XLPE of ness Diamete of - sion - Diamete of - sion - Diamete of .
Insula- PVC of r of Cable. of GI ness r of Cable. of ness r of Cable.
tion Inner PVC Cable. Flat of Cable. GIRoun of Cable.
Sheat Outer Strip. PVC d Wire. PVC
h Sheat Outer Outer
h Sheat Sheat
h h
Sq.mm. mm mm mm mm mm Kgs./Km mm mm mm Kgs./Km mm mm mm Kgs./Km Amps. Amps. Mtrs.
4 Solid 0.7 0.3 1.8 15.0 160 -NA- -NA- -NA- -NA- 1.40 1.24 16.5 510 34 31 1000
4 Stranded 0.7 0.3 1.8 16.0 180 -NA- -NA- -NA- -NA- 1.40 1.24 17.5 560 34 31 1000
6 Solid 0.7 0.3 1.8 16.5 200 -NA- -NA- -NA- -NA- 1.40 1.24 17.5 580 43 50 1000
6 Stranded 0.7 0.3 1.8 17.5 215 -NA- -NA- -NA- -NA- 1.40 1.24 18.5 625 43 50 1000
10 Solid 0.7 0.3 1.8 18.0 250 -NA- -NA- -NA- -NA- 1.40 1.40 19.0 700 57 67 1000
10 Stranded 0.7 0.3 1.8 18.5 260 -NA- -NA- -NA- -NA- 1.40 1.40 20.5 765 57 67 1000
16 Stranded 0.7 0.3 1.8 17.5 350 4 x 0.8 1.40 20.0 715 1.60 1.40 21.0 895 73 70 1000
25 Stranded 0.9 0.3 2.0 21.0 550 -do- 1.40 23.0 940 1.60 1.40 25.0 1150 94 96 500
35 Stranded 0.9 0.3 2.0 23.5 680 -do- 1.40 25.0 1050 1.60 1.40 26.5 1325 113 117 500
50 Stranded 1.0 0.3 2.0 26.0 875 -do- 1.56 28.0 1280 1.60 1.56 29.5 1640 133 142 500
70 Stranded 1.1 0.4 2.2 30.5 1200 -do- 1.56 32.0 1700 2.00 1.56 34.0 2175 164 179 500
95 Stranded 1.1 0.4 2.2 33.5 1530 -do- 1.56 35.0 2100 2.00 1.72 38.0 2775 196 221 500
120 Stranded 1.2 0.5 2.4 37.5 1850 -do- 1.72 39.0 2600 2.00 1.88 42.0 3250 223 257 500
150 Stranded 1.4 0.5 2.6 42.0 2280 -do- 1.88 43.5 3000 2.50 2.04 47.0 4175 249 292 500
185 Stranded 1.6 0.5 2.8 46.5 2800 -do- 2.04 48.0 3650 2.50 2.20 52.0 5000 282 337 500
240 Stranded 1.7 0.6 3.0 52.5 3700 -do- 2.20 54.0 4700 2.50 2.36 57.5 6050 326 399 500
300 Stranded 1.8 0.7 3.2 58.0 4600 -do- 2.36 59.5 5600 3.15 2.52 64.5 7850 367 455 500
400 Stranded 2.0 0.7 3.6 65.5 6000 -do- 2.68 66.5 7000 3.15 2.84 71.5 9500 418 530 500
The above data is approximate and subject to manufacturing tolerance.
* Delivery Length tolerance is ± 5 %. Length more than normal as per customer request.
 cables
Current carrying capacity of
Weight, Dimension data &
TABLE-10 “POLYCAB” FOUR CORE COPPER CONDUCTOR, XLPE INSULATED,
UNARMOURED & ARMOURED CABLE CONFORMING TO IS 7098 PART-1/1988

650/1100 VOLTS WEIGHT AND DIMENSIONS

Nominal Form of Nominal Mini- Unarmoured Cable Formed Wire/ Strip Armoured Cable Round Wire Armoured Cable Current Rating. *Normal
Size Conductor Thick- mum Nominal Approx Approx Nomin Mini- Approx Approx Nomin Mini- Approx Approx In In Air -
of Circular ness Thick Thick- . . al mum . . al mum . . Ground. Deliver
Conduc Shaped of - ness Overall Weight Dimen Thick Overall Weight Dimen Thick Overall Weight y
- tor XLPE ness of Diamete of - sion - Diamete of - sion - Diamete of Length
Insula- tion of PVC r of Cable. of GI ness r of Cable. of ness r of Cable. .
PVC Outer Cable. Flat of Cable. GI of Cable.
Inner Sheat Strip. PVC Roun PVC
Sheat h Outer d Outer
h Sheat Wire. Sheat
h h
Sq.mm. mm mm mm mm mm Kgs./Km mm mm mm Kgs./Km mm mm mm Kgs./Km Amps. Amps. Mtrs.
4 Solid 0.7 0.3 1.8 15.0 260 -NA- -NA- -NA- -NA- 1.40 1.24 16.5 610 43 36 1000
4 Stranded 0.7 0.3 1.8 16.0 280 -NA- -NA- -NA- -NA- 1.40 1.24 17.5 660 43 36 1000
6 Solid 0.7 0.3 1.8 16.5 350 -NA- -NA- -NA- -NA- 1.40 1.24 17.5 730 54 47 1000
6 Stranded 0.7 0.3 1.8 17.5 365 -NA- -NA- -NA- -NA- 1.40 1.24 18.5 775 54 47 1000
10 Stranded 0.7 0.3 1.8 18.5 510 -NA- -NA- -NA- -NA- 1.40 1.40 20.5 1010 72 62 1000
16 Stranded 0.7 0.3 1.8 17.5 750 4 x 0.8 1.40 20.0 1050 1.60 1.40 21.0 1275 92 79 1000
25 Stranded 0.9 0.3 2.0 21.0 1170 -do- 1.40 23.0 1520 1.60 1.40 25.0 1770 119 108 500
35 Stranded 0.9 0.3 2.0 23.5 1550 -do- 1.40 25.0 1915 1.60 1.40 26.5 2190 144 132 500
50 Stranded 1.0 0.3 2.0 26.0 2110 -do- 1.56 28.0 2510 1.60 1.56 29.5 2875 174 162 500
70 Stranded 1.1 0.4 2.2 30.5 2925 -do- 1.56 32.0 3430 2.00 1.56 34.0 3900 210 198 500
95 Stranded 1.1 0.4 2.2 33.5 3880 -do- 1.56 35.0 4450 2.00 1.72 38.0 5125 252 240 500
120 Stranded 1.2 0.5 2.4 37.5 4825 -do- 1.72 39.0 5575 2.00 1.88 42.0 6225 288 276 500
150 Stranded 1.4 0.5 2.6 42.0 6000 -do- 1.88 43.5 6710 2.50 2.04 47.0 7890 324 318 500
185 Stranded 1.6 0.5 2.8 46.5 7380 -do- 2.04 48.0 8225 2.50 2.20 52.0 9580 360 366 500
240 Stranded 1.7 0.6 3.0 52.5 9650 -do- 2.20 54.0 10340 2.50 2.36 57.5 12000 414 426 500
300 Stranded 1.8 0.7 3.2 58.0 12025 -do- 2.36 59.5 13025 3.15 2.52 64.5 15275 462 480 250
The above data is approximate and subject to manufacturing tolerance.
* Delivery Length tolerance is ± 5 %. Length more than normal as per customer request.

COMPANY
AN ISO 9001:2000
1

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1

cables
Current carrying capacity of
Weight, Dimension data &
TABLE-11 “POLYCAB” 650/1100 VOLTS MULTICORE CONTROL CABLE WITH SOLID COPPER CONDUCTOR OF SIZE 1.5 SQ.MM XLPE INSULATED
UNARMOURED, ARMOURED CABLE CONFORMING TO IS 7098 PART - 1/1988

Solid & Stranded $ WEIGHT AND DIMENSIONS

Numbe Nomina Minimu Unarmoured Cable Formed Wire/ Strip Armoured Cable Round Wire Armoured Cable Current Rating. *Norm
r of l m Nomina Approx Approx. Nomin Mini- Approx Approx. Nomina Minimu Approx Approx. In In Air al
Cores Thicknes Thicknes l . Weight al mumThick . Weight l m . Weight Ground. Deliver
s of s of Thicknes Overall of Dimen - ness of Overall of Dimen- Thicknes Overall of y
XLPE PVC s of Diamete Cable. - sion PVC Diamete Cable. sion of s of Diamete Cable. Length
Insula- Inner PVC r of of GI Outer r of GI PVC r of .
tion Sheath Outer Cable. Flat Sheath Cable. Round Outer Cable.
Sheath Strip. Wire. Sheath
No. s mm mm mm mm Kgs./Km mm mm mm Kgs./Km mm mm mm Kgs./Km Amps. Amps. Mtrs.
2 0.7 0.3 1.8 10.0 140 -NA- -NA- -NA- -NA- 1.4 1.24 12.5 370 33 29 1000
3 -do- 0.3 1.8 10.5 160 -NA- -NA- -NA- -NA- 1.4 1.24 13.0 390 25 22 1000
4 -do- 0.3 1.8 11.5 200 -NA- -NA- -NA- -NA- 1.4 1.24 13.5 415 25 22 1000
5 -do- 0.3 1.8 12.5 225 -NA- -NA- -NA- -NA- 1.4 1.24 14.5 465 24 21 1000
6 -do- 0.3 1.8 13.5 250 -NA- -NA- -NA- -NA- 1.4 1.24 15.5 500 22 19 1000
7 -do- 0.3 1.8 13.5 260 -NA- -NA- -NA- -NA- 1.4 1.24 15.5 520 21 18 1000
8 -do- 0.3 1.8 14.5 280 -NA- -NA- -NA- -NA- 1.4 1.24 16.5 580 20 18 1000
9 -do- 0.3 1.8 15.5 315 -NA- -NA- -NA- -NA- 1.4 1.24 17.5 630 19 17 1000
10 -do- 0.3 1.8 17.0 340 -NA- -NA- -NA- -NA- 1.4 1.24 18.5 655 18 16 1000
12 -do- 0.3 1.8 17.5 390 -NA- -NA- -NA- -NA- 1.4 1.24 19.0 720 17 15 1000
14 -do- 0.3 1.8 18.0 430 -NA- -NA- -NA- -NA- 1.4 1.40 20.0 825 16 14 1000
16 -do- 0.3 1.8 18.5 475 4 x 0.80 1.40 19.0 750 1.6 1.40 21.0 925 16 14 1000
19 -do- 0.3 1.8 19.5 540 -do- -do- 20.0 815 1.6 1.40 22.0 1010 15 13 1000
21 -do- 0.3 2.0 20.5 600 -do- -do- 21.0 900 1.6 1.40 23.0 1150 14 12 500
24 -do- 0.3 2.0 22.5 665 -do- -do- 23.0 1000 1.6 1.40 25.0 1250 13 12 500
27 -do- 0.3 2.0 23.0 750 -do- -do- 23.5 1050 1.6 1.40 25.5 1330 13 11 500
30 -do- 0.3 2.0 23.5 820 -do- -do- 24.0 1125 1.6 1.40 26.0 1400 12 11 500
33 -do- 0.3 2.0 24.0 910 -do- -do- 25.0 1225 1.6 1.40 27.0 1475 12 10 500
37 -do- 0.3 2.0 25.0 975 -do- -do- 26.0 1325 1.6 1.40 28.0 1550 11 10 500
44 -do- 0.3 2.0 28.0 1150 -do- -do- 28.5 1500 1.6 1.56 30.5 1850 11 9 500
52 -do- 0.3 2.0 29.0 1300 -do- 1.56 30.5 1700 1.6 1.56 32.0 2050 10 9 500
61 -do- 0.4 2.2 31.0 1500 -do- 1.56 32.0 1950 2.0 1.56 34.5 2550 9 8 500
$ The Weight and Dimensions of Cables with Stranded conductor will be comparatively more than that of Solid conductor,whereas all other
parameters are same.. The above data is approximate and subject to manufacturing tolerance.
* Delivery Length tolerance is ± 5 %. Length more than normal as per customer request.
 cables
Current carrying capacity of
Weight, Dimension data &
TABLE-12 “POLYCAB” 650/1100 VOLTS MULTICORE CONTROL CABLE WITH SOLID COPPER CONDUCTOR OF SIZE 2.5 SQ.MMXLPE INSULATED
UNARMOURED, ARMOURED CABLE CONFORMING TO IS 7098 PART - 1/1988

Solid & Stranded $ WEIGHT AND DIMENSIONS

Numbe Nominal Minimum Unarmoured Cable Formed Wire/ Strip Armoured Cable Round Wire Armoured Cable Current Rating. *Norm
r of Thicknes ThicknesNominal Approx Approx. Nomin Minimu Approx Approx. NominaMinimum Approx Approx. In In Air al
Cores s of s of Thicknes . Weight al m . Weight l Thicknes . Weight Ground. Deliver
XLPE PVC s of Overall of Dimen Thick- Overall of Dimen- s of Overall of y
Insula- Inner PVC Diamete Cable. - sion ness of Diamete Cable. sion of PVC Diamete Cable. Length
tion Sheath Outer r of of GI PVC r of GI Outer r of .
Sheath Cable. Flat Outer Cable. Round Sheath Cable.
Strip. Sheath Wire.
No. s mm mm mm mm Kgs./Km mm mm mm Kgs./Km mm mm mm Kgs./Km Amps. Amps. Mtrs.
2 0.7 0.3 1.8 11.5 185 -NA- -NA- -NA- -NA- 1.4 1.24 13.5 380 39 32 1000
3 -do- 0.3 1.8 12.0 220 -NA- -NA- -NA- -NA- 1.4 1.24 14.0 425 34 30 1000
4 -do- 0.3 1.8 13.0 260 -NA- -NA- -NA- -NA- 1.4 1.24 14.5 500 34 30 1000
5 -do- 0.3 1.8 14.0 300 -NA- -NA- -NA- -NA- 1.4 1.24 15.5 525 31 28 1000
6 -do- 0.3 1.8 15.0 340 -NA- -NA- -NA- -NA- 1.4 1.24 16.5 600 29 26 1000
7 -do- 0.3 1.8 15.0 360 -NA- -NA- -NA- -NA- 1.4 1.24 16.5 625 27 25 1000
8 -do- 0.3 1.8 16.0 400 -NA- -NA- -NA- -NA- 1.4 1.24 18.0 700 26 24 1000
9 -do- 0.3 1.8 16.5 450 -NA- -NA- -NA- -NA- 1.4 1.40 19.5 800 25 22 1000
10 -do- 0.3 1.8 17.5 475 4 x 0.80 1.24 19.0 700 1.6 1.40 21.0 875 24 21 1000
12 -do- 0.3 1.8 18.0 550 4 x 0.80 1.40 19.5 760 1.6 1.40 21.5 975 22 20 1000
14 -do- 0.3 1.8 19.0 625 4 x 0.80 1.40 20.0 850 1.6 1.40 22.0 1050 21 19 1000
16 -do- 0.3 2.0 20.5 680 4 x 0.80 1.40 21.5 920 1.6 1.40 23.5 1160 20 18 1000
19 -do- 0.3 2.0 21.5 770 4 x 0.80 1.40 22.5 1025 1.6 1.40 24.5 1250 19 17 1000
21 -do- 0.3 2.0 22.5 860 4 x 0.80 1.40 23.5 1140 1.6 1.40 25.5 1350 18 16 500
24 -do- 0.3 2.0 24.5 950 4 x 0.80 1.40 25.5 1250 1.6 1.40 27.5 1500 17 16 500
27 -do- 0.3 2.0 25.5 1050 4 x 0.80 1.40 26.5 1350 1.6 1.40 28.5 1625 16 16 500
30 -do- 0.3 2.0 26.0 1150 4 x 0.80 1.40 27.5 1550 1.6 1.40 29.0 1760 16 14 500
33 -do- 0.3 2.0 27.0 1250 4 x 0.80 1.40 28.5 1630 1.6 1.56 30.5 1950 15 14 500
37 -do- 0.3 2.0 28.0 1350 4 x 0.80 1.40 29.5 1710 1.6 1.56 31.5 2080 15 13 500
44 -do- 0.4 2.2 32.0 1650 4 x 0.80 1.56 33.0 2100 2.0 1.56 35.5 2600 14 12 500
52 -do- 0.4 2.2 33.5 1950 4 x 0.80 1.56 34.5 2350 2.0 1.56 37.5 2900 13 12 500
61 -do- 0.4 2.2 35.0 2150 4 x 0.80 1.56 36.0 2625 2.0 1.56 39.0 3400 12 11 500

COMPANY
AN ISO 9001:2000
$ The Weight and Dimensions of Cables with Stranded conductor will be comparatively more than that of Solid conductor,whereas all other
parameters are same.. The above data is approximate and subject to manufacturing tolerance.
* Delivery Length tolerance is ± 5 %. Length more than normal as per customer request.
1

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Rating Factors

1) FOR AIR AND GROUND TEMPERATURE

A. Rating factors for variation in ambient air temperature
Ambient Temp (°C) 25 30 35 40 45 50
Rating Factors 1.14 1.10 1.04 1.00 0.95 0.90
B. Rating factors for variation in ground temperature
Ground Temp (°C) 15 20 25 30 35 40
Rating Factors 1.12 1.08 1.03 1.00 0.96 0.91

2) FOR DEPTH OF LAYING ( CABLES LAID DIRECT IN THE GROUND).

Depth of laying Size
Cm Upto 25 mm2 Above 25 mm2 Upto 300 mm2 Above 300 mm2
75 1.0 1.00 1.00
90 0.99 0.98 0.97
105 0.98 0.97 0.96
120 0.97 0.96 0.95
150 0.96 0.94 0.92
180 or more 0.95 0.93 0.91

3) FOR VARIATION IN THERMAL RESISTIVITY OF SOIL

( TWIN AND MULTICORE CABLES LAID DIRECT IN THE GROUND).

Nominal area Two cables touching for values of Thermal Resistivity of soil in °C cm / W
of conductor 100 120 150 200 250 300
mm2
1.5 1.10 1.05 1.00 0.92 0.86 0.81
2.5 1.10 1.05 1.00 0.92 0.86 0.81
4 1.10 1.05 1.00 0.92 0.86 0.81
6 1.10 1.05 1.00 0.92 0.86 0.81
10 1.10 1.06 1.00 0.92 0.85 0.80
16 1.12 1.06 1.00 0.91 0.84 0.79
25 1.14 1.08 1.00 0.91 0.84 0.78
35 1.15 1.08 1.00 0.91 0.84 0.77
50 1.15 1.08 1.00 0.91 0.84 0.77
70 1.15 1.08 1.00 0.90 0.83 0.76
95 1.15 1.08 1.00 0.90 0.83 0.76
120 1.17 1.09 1.00 0.90 0.82 0.76
150 1.17 1.09 1.00 0.90 0.82 0.75
185 1.18 1.09 1.00 0.89 0.81 0.75
240 1.18 1.09 1.00 0.89 0.81 0.75
300 1.18 1.09 1.00 0.89 0.81 0.75
400 1.19 1.10 1.00 0.89 0.81 0.75

20
 ©

Group Rating Factors

AN ISO 9001:2000 COMPANY

FOR SINGLE CORE CABLES

A) Cables laid direct in the ground in horizontal formation.
Distance between Trefoils
No. of Trefoils in Group
Touching 15 cm 30 cm 45 cm
2 0.78 0.81 0.85 0.88

3 0.68 0.71 0.77 0.81

4 0.61 0.65 0.72 0.76

5 0.56 0.61 0.68 0.73

B) Cables laid in ducts in horizontal formation.

Distance between Trefoils
No. of Trefoils in Group
Touching 45 cm 60 cm

2 0.87 0.90 0.91

3 0.79 0.83 0.86

4 0.74 0.79 0.82

5 0.71 0.76 0.80

C) Cables laid on racks / Trays in covered trench with having restricted air circulation, Trefoils are separated by
two cable diameter horizontally and the trays are in tiers having 30 cm distance.
No. of Trefoils in Horizontal Formation
No. racks / trays in tiers
1 2 3
1 0.95 0.90 0.88

2 0.90 0.85 0.83

3 0.88 0.83 0.81

6 0.86 0.81 0.79

D) as above C. but cables laid in open air.

No. of Trefoils in Horizontal Formation
No. racks / trays in tiers
1 2 3
1 1 0.98 0.96

2 1 0.95 0.93

3 1 0.94 0.92

6 1 0.93 0.90

21
Group Rating Factors

FOR MULTI CORE CABLES

A) Cables laid on cable trays exposed to air, the cables spaced by one cable diameter and trays are in
tiers spaced by 30 cm. The clearance between the wall and the cable is 25 mm.
No. of cables trays in No. of Cables per Tray
tier 1 2 3 6 9
1 1 0.98 0.96 0.93 0.92
2 1 0.95 0.93 0.90 0.89
3 1 0.94 0.92 0.89 0.88
6 1 0.93 0.90 0.87 0.86

B) Cables laid inside concrete trench with removable covers on cable trays having restricted circulation. The
cables spaced by one cable diameter and trays are in tiers spaced by 30 cm. The clearance of the
cable from the wall is 25 mm.
No. of cables trays in No. of Cables per Tray
tier 1 2 3 6 9
1 0.95 0.90 0.88 0.85 0.84
2 0.90 0.85 0.83 0.81 0.80
3 0.88 0.83 0.81 0.79 0.78
6 0.86 0.81 0.79 0.77 0.76

C) Cables laid on cable trays exposed to air, the cable touching and trays are in tiers spaced by 30 cm.
The clearance between the wall and the cable is 25 mm.
No. of cables trays in No. of Cables per Tray
tier 1 2 3 6 9
1 1 0.84 0.80 0.75 0.73
2 1 0.80 0.76 0.71 0.69
3 1 0.78 0.74 0.70 0.68
6 1 0.76 0.72 0.68 0.66

D) Cables laid direct in ground in horizontal formation.

Distance of Cables
No. of cables in
Group Touching 15 cm 30 cm 45 cm
2 0.79 0.82 0.87 0.90
3 0.69 0.75 0.79 0.83
4 0.62 0.69 0.74 0.79
5 0.58 0.65 0.72 0.76
6 0.54 0.61 0.69 0.75

E) Cables laid in single way ducts / pipes in horizontal formation.

Distance of Cables
No. of cables in
Group Touching 30 cm 45 cm 60 cm
2 0.88 0.90 0.92 0.94
3 0.82 0.84 0.87 0.89
4 0.77 0.80 0.84 0.87
5 0.74 0.78 0.82 0.85
6 0.71 0.76 0.81 0.84

22
 ©

Handling, Storage and Laying of Polycab Cables

AN ISO 9001:2000 COMPANY

A. CABLE INSPECTION B. CABLE HANDLING

Inspect every cable reel for damage & STORAGE
before accepting the shipment.Be Damage to cables can occur due
particularly alert for cable damage to the incorrect handling to which
if: the drums and cables may be
1. A reel is lying flat on its side subjected; causing breakdown of
the drum flanges and in
2. Several reels are stacked exceptional cases, movement of the
3. Other freight is stacked on a reel drum barrel takes place. Once this
breakdown of the drum occurs, the
4. Nails have been driven into reel cable is immediately exposed to
flanges to secure shipping damage. Cables damaged during
blocks handling & storage can cause
5. A reel flange is damaged service failures when the subject
cable is put to use.
6. A cable covering is removed,
stained or damaged Thus the following is a list of Do’s
and Don’ts that should be
7. A cable end seal is removed or followed while handling and
damaged. A reel has been storing the cables before it is put
dropped (hidden damage to use.
likely)

Do’s Don’ts
When off loading reels from a truck, Never drop reels. If reels must be rolled,
lower reels carefully using a hydraulic roll in opposite direction of the cable
gate, hoist or forklift truck wraps to keep cable from loosening on
the reel.

If a fork lift is used, approach the reel Do not allow the lift forks to contact the
from the flange side. Position the forks cable. Care must be taken by the fork lift
such that the reel is lifted by both operator not to make sudden turns or
reel flanges. Also Consideration stops.
should be given to, Traffic patterns
during off-loading & damage dur- ing
the time in storage

Cable reels should be stored on Multiple reels stacked on top of each

hard sur- faces resting on the other (“Pancake” storage) is not
flanges edge (flanges vertical). Align recommended for cable drums. The
reels flange to flange and, if weight of the stack can total thousands of
possible, arrange so that first in is kgs. creating an enormous load on the
first out. bottom reel. Also, damage to the reel and/
or cable will likely occur when the reel is
flipped for transit. A concentration of
stress on the reel flange may cause it to
break and subsequently damage the
cable.

23
 When using a hoist, install a This may lead to the bending of the reel
mandrel through the reel arbor flanges and mashing the cable
holes and attach a sling. Use a
spreader bar approximately 6 inches
longer than the overall reel width
placed between the sling ends just
above the reel flanges.

24
Handling, Storage and Laying of Polycab Cables

C. PRE- INSTALLATION 5. Under no circumstances the

To ensure safety during cable cable winding shall be lifted off a
installation, following shall be coil or drum lying flat at the
checked prior to installation. flanges. This would cause
1. The cable selected is proper serious twist and damages.
for designed application. 6. Suitable protection shall be
2. The cable has not been provided to the cables against
damaged in transit or storage. mechanical damages, it includes
Review all applicable state and covers, pipes etc.
national codes to verify that the
cable chosen is appropriate for E. RECOMMENDED
the job. Also consult your local MINIMUM BENDING RADIUS
electricity authority. Next, you must
identify any existing cable damage FOR HEAVY DUTY CABLES.
and prevent any further damaged Single Core : 20
from occurring. This is done
through proper cable inspection, x D Multicore :
handling and storage. 15 x D

D. INSTALLATION & LAYING Where D = Diameter of cable in mm

Mechanical stresses during
installation are generally more F. RECOMMENDED
severe than those encountered SAFE PULLING FORCE
while in service. Thus care should WITH STOCKINGS:
be taken as regards to the following a) For Unarmoured Cable : P = 5 D2
while installation and laying of
cables. b) For Armoured Cable : P = 9 D2
1. Polycab recommend the Where P = Pulling Force
laying and installation of Where D = Diameter of cable in mm
cables as per IS: 1255/84.
2. Care shall be taken during G. RECOMMENDED SAFE
laying to avoid sharp bending, PULLING FORCE WHEN PULLED
and twisting. WITH PULLING EYE :
3. Cable shall be un wound from the
drum by lifting the drum on the a) For Aluminium Conductor : 30 N/mm2
center
b) For Copper Conductor : 50 N/mm2
4. Shaft supported both ends
with suitablejacks / stands.

DO NOT ATTEMPT “COILING” OF CABLE ON THE

GROUND

ON THE GROUND CABLE CAN BE FLAKED IN A FIGURE OF EIGHT

FORMATION

25
 Note: R Minimum Permissible bending radius of
cable.

2
 Production Facilities at Daman Factory
POLYCAB REGIONAL OFFICES
CHENNAI : Old No. 5/2, New No.9/2 Gopalkrishna Road, T-Nagar, CHENNAI - pune@polycab.com
600 017. Tel: 044 42022775 / 28152725 • Fax: 044 42022774 • Email : BANGALORE : 104/6, 5th Cross, 5th Block, Rajajinagar, BANGALORE
chennai@polycab.com - 560 010. Tel: 080 23102172 • Fax: 080 23102071 • Email :
BARODA : 9, Khushbu Corner, 56, Vishwas Colony, Alkapuri, BARODA - karnataka@polycab.com
390 005.
Tel: 0265 3252825 / 3083838 • Fax: 0265 3083366 • Email :
gujarat@polycab.com
PUNE : A7, Akshay CHS, South Koregaon Park, Opp Seasons Service Apt.
PUNE - 01. Tel: 0265 3252825 • Fax: 0265 3252825 • Email :
SECUNDERABAD : 401, A, Suryakiran Complex, Sarojini Devi Road,
SECUNDERABAD - 500 003.
Tel: 040 66326228 • Fax: 040 66326229 • Email : andhra@polycab.com
DELHI : 901-B, 909, 9th Floor, Devika Towers, Nehru Place, NEW DELHI -
110 019. Tel: 011 26453056/57 • Fax: 011 26453058 • Email :
north@polycab.com
KOLKATTA : 1st Floor, 34, Dr. Meghnad Saha Sarani, (Formally Southern
Avenue), Kolkata-700 029. • Email: kolkatta@polycab.com

2
 Wiring the World

WIRES & CABLES

Polycab Wires PVt. ltd.

(an ISO 9001:2000 Company)

Regd. & Head office :

Polycab House, 771, Pandit Satawalekar Marg,
Mahim (W), Mumbai 400 016.
Tel. : 91-22-2432 7070 - 4, 2436 2199, 2432 9118
Fax : 91-22-2432 7075
E-mail :
info@polycab.com Website
: www.polycab.com
POLYCAB WIRES PVT. H.T. AERIAL BUNCHED CABLES
LTD.

ABOUT US

From a modest beginning with Conductors, Compounds and Wires & Cables, almost
three decades ago, the Polycab Group Set up a State of Art manufacturing facilities at
Daman in 1997, to address key market determinants. Starting the project from scratch
Polycab was able to design a manufacturing facility around State of Art disciplines of
Computer integrated manufacture .The Quality & Manufacturing setup is sourced out
from the World renowned Machinery and Technology Suppliers with constant
upgradations and expansions.

At POLYCAB, We study the requirements of the penultimate users with our

commitment for Quality and Value. These are converted into process specifications
based on Indian & International Standards.

In India with economic reforms and gradual opening of economy to the global system,
the Power sector has become one of the key areas of attention of everybody concerned.

Efficient and dependable power system being the requisite, Aerial Bunched Cable is
the item which is receiving attention of all public sector as well as private sector power
distributors. It is expected that in the coming years, use of aerial bunched cables will rise
phenomenally all over India.

EXPERIENCE:

After extensive research Polycab has successfully developed and introduced Aerial
Bunched Conductor Cables, and have already achieved technical competence,
manufacturing ability, and marketing experience by supplying ABC cables to the
following Customers: -

1. BSES LTD (for Gridco – Orissa)

2. North Delhi Power Ltd - Delhi

TAILOR MADE DESIGN

POLYCAB have recognized the need for H.T & L.T ABC cables in the emerging
market due to thrust in the Transmission & Distribution network revamping programme
by Govt. of India. We can interact with you to design for you H.T. & L.T. Aerial
Bunched Cables to meet your specific requirements.

Page 1 of 3
POLYCAB WIRES PVT. LTD. H.T. AERIAL BUNCHED CABLES
AN ISO-9001 COMPANY

AERIAL BUNCHED
CABLES

INTRODUCTION

Aerial Bunched Cable (ABC) is a very novel concept for Over Head power
distribution. When compared to the conventional bare conductor over head distribution
system, ABC provides higher safety and reliability, lower power losses and ultimate
system economy by reducing installation, maintenance and operative cost. This system
is ideal for rural distribution and specially attractive for installation in difficult terrains
such as hilly areas, forest areas, coastal areas etc.

ABC is also considered to be the best choice for power distribution congested urban
areas with narrow lanes and by-lanes. In developing urban complex, ABC is the better
choice because of flexibility for rerouting as demanded by changes in urban
development plan. Aerial bunched cable system is specially suited in limited space
conditions like densely populated areas where laying of underground cables is
impossible or extremely expensive

Most of the faults in overhead power supply systems occur due to failure in transmission
lines, whether these are HT or LT, resulting in immense loss and inconvenience to
consumers. The main weakness of overhead lines are that its power carrying conductors
are bare.

To overcome the above deficiency, Aerial Bunched Cable systems have been introduced
at many places across the world for both HT and LT systems. Principally, the system is
a compromise between insulated power cable systems and bare overhead conductor
systems. As far as basic construction goes, there are three or four power carrying
conductors suitably insulated and laid around a bare or insulated weight-carrying
conductor, which also serves as earth/neutral conductor. The cable is then hanged on
transmission poles/towers suitably. Since the cores are insulated the chances of faults
reduces to a great extent. While it lacks the mechanical strength and safety of
underground cables, the very fact that it is hanged overhead enables it to avoid
mechanical abuses that an underground cable is normally subjected to.

In comparison to bare overhead lines, aerial bunched cable has very high degree of
safety and reliability due to the conductors being insulated with the best dielectric
medium. This ensures good protection against ground and line faults leading to
considerable increase in system efficiency as against bare overhead lines. The problem
of free-clearance is also minimized.

Tampering with power-line like hooking also gets eliminated, resulting in much more
efficient utilization of power.

Page 2 of 3
POLYCAB WIRES PVT. H.T. AERIAL BUNCHED CABLES
LTD.
HT AERIAL BUNCHED CABLES

While specifically talking about HT Aerial Bunched Cables, these are basically three
single cored unarmored cables laid around a weight carrying conductor which also
serves as an earth or neutral conductor.

TYPICAL CONSTRUCTIONAL DETAILS (H.T. ABC):

POWER CORES

Conductor: Composed of H2/H4 grade Aluminium to class 2 grade of IS 8130 or IEC

60228 or other equivalent standards. It can be from 35 mm2 to 300 mm2.

Conductor Screen: (applicable for cables above 3.3 kV grade)

Extruded semiconducting layer as per IS 7098 (Part 2) or IEC 60502 or any other
equivalent international standard.

Insulation: Typically this may be XLPE insulation as per IS 7098 (Part 2) or IEC 60502
which gives both material property as well as thickness level required.

Insulation screen: Wherever applicable (mostly 6.6 kV onwards) it comprises of an

extruded layer of semiconducting material followed by a metallic tape (mostly copper).

Jacket: ST2 grade PVC to IS 5831.

MESSENGER WIRE

This typically consists of either strands of Aluminium alloy wire to IS 398 (Part ) or
galvanized steel wire to BS 183 as chosen by the customer. It may have a jacket similar
to Power cores.

Core identification: By printing numbers 1,2,3 on the jackets of Power cores and 0 on
the jacket of messenger core.

We can supply the cable to other international standards like IEC, BS, etc or to
customers own specifications and needs.

POLYCAB WIRES PVT. LTD.

Hico House, 1st Floor, Pandit Satwalekar Marg,
Mahim, Mumbai – 400 016
Tel: 91-22-28362580, Fax:91-22-24327075
E-mail: polycab@vsnl.com Internet: www.polycab.com

Page 3 of 3
WIRES & CABLES
WIRES & CABLES

Ans odncsion
ables are the source of

C
carrying power and signal in power ❖ IEC-60332 Part 1 & 3
plants, refineries, process industries. ❖ SS-4241417
Cable network can carry fire from
one place to another in the event of Flame Retardant Cables are those
fire caused due to which retards flame in the event of fire.
external sources or due to short circuit. These are normally used in buildings,
process plants, refineries and
Experience reveals that electrical substations.
cables are the prime source of
propagation of fire. It is also ADVANTAGES OF POLYCAB F R
experienced that damage to property CABLES
and human life due to this phenomenon  Does not allow fire propagation in
needs to be given due importance and single cable.
the cables shall be selected
 Does not propagate fire when cables
considering fire and safety
are laid in bunch or in trays
requirements of circuit integrity
during fire conditions. It includes  Extinguishes flame immediately
emergency Power Supply, Alarm after fire temperature goes down
Power Supply and other critical
applications. CONSTRUCTION – F R
CABLES
Cables used in enclosed areas such as
Power Plants, Buildings, Housing 1. Conductor: Annealed Plain /
Complex, Multiplexes, Underground Annealed Tinned Copper /
Railways, Road Tunnels, Hospitals Aluminium - IS:8130 / IEC 60228 /
shall be Flame Retardant. Flame BS 6360.
Retardant Low Smoke & Halogen or
Low Smoke & Halogen Free or Fire 2. Insulation: PVC as per IS:1554, IEC-
Resistant (Fire Survival Cables) used 60502/BS 6746 OR XLPE as per
for critical applications. IS:7098, IEC-60502/BS 5467, BS
6622.
POLYCAB manufactures these types of 3. Inner Sheath/Bedding: ST1/ST2
cables having constructions as per PVC, FR PVC, IS / IEC 60502.
standard specifications – IS:1554,
IS:7098, IEC:60502, BS:5467, BS:6746, 4. Armouring: Unarmoured /
BS:6622 & BS:7835 up to 33 kV. Galvanized Steel (or Aluminium for
Single Core) Round / Strip
POLYCAB FR Armoured to IS:3975/IEC- 60502,
BS 6746/5467/6622.
CABLES
5. Outer Sheath: FR PVC ST1/FR PVC
❖ IS-10810 Pt. 62 All categories/IS- ST2.
1554-FR 6. FR Properties: IEC-60332-1 &
❖ IS-10810 Part 61 / IS-1554, IS-694 3 SS-4241417, IEEE-383, ASTM-D-
❖ IEEE – 383 2863.
❖ ASTM-D-2863 ● ● ● ● ● ●

1
WIRES & CABLES

POLYCAB FRLS CONSTRUCTION – FRLS CABLES

CABLES
1. Conductor: Annealed Plain /
❖ IS-10810 Part 62 / IS-1554 Annealed Tinned Copper /
❖ IS-10810 Part 61 / IS-1554 Aluminium - IS:8130 / IEC 60228 /
❖ IEC-60332 Part 1 & 3 BS 6360.
❖ SS-4241417 2. Insulation: PVC as per IS:1554, BS
❖ IEEE – 383 IEC- 60502/BS 6746 OR XLPE as
❖ ASTM-D–2843 & D-2863 per IS:7098, IEC-60502/BS 5467.
❖ IEC – 60754 - 1 3. Inner Sheath/Bedding: ST1/ST2
PVC, FRLS PVC, IS/IEC.
Flame Retardant Low Smoke Cables 4. Armouring: Unarmoured /
are designed specially for Power Galvanized Steel (or Aluminium for
Plants, public premises such as Single Core) Round / Strip Wire
Cinemas, Multiplexes, theaters, Armoured to IS:3975/IEC-60502, BS
Airports, Hospitals, Super Markets and 6746/5467.
underground railway, where risk to
human life due to fire and smoke is 5. Outer Sheath: FRLS PVC ST1 /
high. FRLS PVC ST2, IS/IEC.
6. FRLS Properties: IEC-60332-1 & 3,
Human life gets endangered due to IEC-
smoke and suffocation in the event of 60754-1, SS-4241417, IEEE-383,
fire. ASTM-D-
2863, ASTM-D-2843.
Polycab FRLS-H cables are
manufactured with special PVC outer ● ● ● ● ● ●
sheath which is formulated for Lower
smoke and Halogen content.
POLYCAB HALOGEN
ADVANTAGES OF POLYCAB FREE
FRLS - H CABLES
CABLES
❖ IS-9968-1, 7098
meets standard
❖ BS-6724, 7655
▪ Does not allow fire propagation in
❖ IEC-60502-1, 60332-1,2,3, 60754-2
single and multi layered or bunched
cables. ❖ SS-4241417
❖ IEEE – 383
▪ Does emit limited smoke in case of
❖ ASTM-D–2843 & D-2863
fire.
▪ Does emit limited toxic and
halogen gases
▪ Does have high temperature index.

2
WIRES & CABLES

LSZH (Low Smoke Zero Halogen), CONSTRUCTION – LSZH / LSOH /

LSOH (Low Smoke Zero Halogen), ZHFR CABLES
ZHFR (Zero Halogen, Flame
Retardant) are the common
nomenclature of cables which are 1. Conductor: Annealed Plain /
latest in the design and are invariably Annealed Tinned Copper /
recommended by various consultants Aluminium - IS:8130 / IEC 60228 /
and users for high human safety BS 6360.
requirement in case of fire. 2. Insulation: XLPE, EPR, Silicon as
per IS:9968-1, IS 7098, BS:6724 &
These Halogen Free Cables does not IEC – 60502, BS - 7846
emit toxic gases and hence does not
suffocate human beings during fire, 3. Inner Sheath/Bedding: Low smoke
causing fire fighting easy and reducing Zero Halogen / Flame Retardant
risk to human life. Compound.
4. Armouring: Unarmoured /
These cables are invariably used in Galvanized Steel (or Aluminium for
underground transport / Railway, and Single Core) Round / Strip Wire
are recommended of all such areas Armoured to IS:3975/IEC-60502, BS
where fire associated risk to human life 6724.
is more.
5. Outer Sheath: Low smoke Zero
Halogen / Flame Retardant
ADVANTAGES OF POLYCAB Compound.
LSZH / LSOH / ZHFR CABLES
6. Properties: IEC-60332-1 & 3, SS-
4241475, IEEE-383, ASTM-D-2863,
 Does not allow fire propagation in ASTM-D-2843, IEC-60754-1,
single and multi layered or bunched BS:7655.
cables.
 Does emit limited smoke in case of ● ● ● ● ● ●
fire.
 Does not emit toxic gases hence POLYCAB FIRE
safe to human and electronic RESISTANT
equipments
 Low and white smoke does not
/ FIRE SUR-VIVAL
effect visibility in enclosed areas CABLES
❖ BS-7846, 7655
 All cable components are non-toxic,
having low emission of smoke and ❖ BS-6387 Category ABC & XYZ
acidic nature. ❖ IEC-60331, 60332 Part 1 & 60332 Part
3
3
WIRES & CABLES

The cables which are used in the

Power, Control or Signal Circuit of CONSTRUCTION – FIRE
emergency equipments shall be Fire RESISTANT / FIRE SURVIVAL
CABLES
Resistant to ensure higher safety and
performance in the event of fire. 1. Conductor: Annealed Plain / Tinned
Copper / Aluminium - IS:8130 / IEC
These critical equipments connected 60228/ BS 6360.
with the cable such as Alarm, Lift 2. Fire Barrier: Layers of Glass Mica
Power Supply, Emergency, Lights, exit Tape.
lights, water spray system and other 3. Insulation: EPR or XLPE or Silicone
important functions. Rubber.

ADVANTAGES OF POLYCAB 4. Fire Barrier Tape: Glass Tape

FIRE RESISTANT (FIRE 5. Inner sheath: FRLS / LSZH
SURVIVAL)
– FS CABLE 6. Armour : IS: 3975, BS: 7846
7. Outer Sheath: FRLS PVC ST 2,
 Maintains the circuit in operation LSZH / LSOH.
for few hours to ensure emergency
operation in the event of fire.
Fire Resistant or Fire Survival Cables
 Ensures Power availability during shall be with LSZH / LSOH / ZHFR
fire. sheathing for better performance
 Can save life and damages in the under fire.
event of fire.
 Does not emit toxic gases hence ● ● ● ● ● ●
safe to human and electronic
equipments
 Low and white smoke does not
effect visibility in enclosed areas
 All cable components are non-toxic,
having low emission of smoke and
acidic nature.

4
WIRES & CABLES

Performance Characteristics of Different Types of Cables under Fire

Sl. Cable Type Fire Application Properties
No. Characteristics

01 PVC Cables Flame Where flame IEC – 60332 – 1, 332 – 3

Retardant retardance
XLPE Cable (FR) is desirable, but smoke SS-4241417, ASTM-D-2863 – Limiting
Oxygen
and acid gas evolution Index – Min. 29%
is
not considered to pose
a
serious hazard.

02 Low emission Flame In situations where IEC – 60332 – 1, 60332 – 3, SS – 424 –

Retardant, 1417
PVC Cables, Low Smoke & reduced levels of smoke ASTM-D-2843, Smoke Density Rating:Max.
60%
XLPE Cables Reduced and corrosive gases are ASTM-D–2863,Limiting Oxygen
Index:Min.29%
Halogen (FRLS- needed, compared to IEEE-60754–1 (Max. HCL Gas Emission):
H) ordinary PVC or 20%)
chlorinated polymer
based cables.

03 Low Fire Flame For installation in areas IEC – 60332 – 1, 60332 – 3, SS – 424 –
Retardant 1417
Hazard Low Low smoke & where smoke and acid ASTM-D-2843, Smoke Density Rating:
Max.20%
Smoke, Zero Acid Gas gas evolution could IEC-61034, Min. Light Transmission:
pose 70%
Halogen. Emission. a hazard to personnel ASTMD–2863,Limiting Oxygen Index:Min.
or 30%
(LSOH) sensitive equipment, IEC-60754-2, Max. HCL : 0.5%
but
where circuit integrity Toxicity Index: Less than 5
is
not needed. NES 713, BS – 6724

04 Limited Fire Resistance For maintaining IEC – 60331, 60332 – 1, 60332 – 3, SS –

Circuit / essential 424 –
Integrity Fire Survival / circuits such as 1417
reduced Flame emergency lighting and ASTM-D-2843, Smoke Density Rating:
Retardant 60%
hazard - Low Smoke fire alarms for shorter ASTM-D–2863, Limiting Oxygen Index:
Min.
Halogen (FRLS-H) & time periods. 29%
Increased
contents Reduced hazard from smoke and IEEE-60754–1 (Max. HCL Gas Emission):
(FRLS, FS) Halogen acid gas emission. 20%)

05 Limited Fire Resistant / For maintaining IEC – 60331, 60332 – 1, 60332 – 3, SS –

Circuit essential 424 –
Integrity – Fire Survival / circuits such as 1417
Low
Fire & Gas Flame emergency lighting and ASTM-D-2843, Smoke Density Rating:
Retardant Max.20%
Hazards. Low Smoke & fire alarms for shorter IEC-61034, Min. Light Transmission:
70%
(FS Cable, Zero Halogen. time periods. Reduced ASTMD–2863, Limiting Oxygen Index:
Min.
(LSOH) hazard from cable 30%
combustion. IEC-60754-2, Max. HCL : 0.5%
Toxicity Index: Less than 5
NES 713,
BS – 7846, BS – 6387

5
WIRES & CABLES

IMPORTANTTESTS
TESTS TO ENSURE CIRCUIT INTEGRITY AS PER IEC - 60331

Test Procedure:

The test sample is exposed to

flame
for 3 hrs. at o with
750 rated
C to
voltage being applied cable.

3 Amps. fuses shall not blow off.

Test Equipment:

Horizontal burner (Flame source)

with sample support arrangement.

SMOKE DENSITY TEST AS PER ASTM D-

2843

Test Procedure:

The test sample is exposed to flame at

a 40 psi pressure for 4 minute, the
light absorption data are plotted on a
graph as time versus smoke density
(%).

Test Equipment:

Smoke density Chamber with specimen

holder, Ignition system and photometric
system complete.

6
WIRES & CABLES

SWEDISH CHIMNEY TEST

AS PER SS – 424 1417

Test Procedure:

Measured quantity of ethanol is used to create

flame which is applied on 850 mm. long cable
for a calculated time and the un-burnt lengths
from the top is measured.

Test Equipment:

Vertical Steel Tube with rectangular openings, lid

and conical tray for ignition fluid.

OXYGEN INDEX TEST

AS PER ASTM-D-2863

Test Procedure:

Test sample 7 to 15 cm long by 6.5 +

0.5 mm wide over 3 + 0.5 mm thick in
a minimum concentration of oxygen
in a N2 + O2 mixture just support
candle like burning at room
temperature.

Test Equipment:
Oxygen Analyser, Flame source, Oxygen
& Nitrogen gas supply and measuring
flow meter.